Manualde taller ktm 400 600 lc4 2003

400-660LC42003
REPAIR MANUAL
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
ART.NR.: 3.206.006-E
MANUAL DE REPARACIÓN
KTM Group Partner
400-660LC4
REPAIR
MANUAL
1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING THE ENGINE
5 SERVICING ON INDIVIDUAL COMPONENTS
6 ASSEMBLING THE ENGINE
7 ELECTRICAL
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 TECHNICAL SPECIFICATIONS
11 PERIODIC MAINTENANCE SCHEDULE
12 WIRING DIAGRAMS
13
14
15
16
I M P O RTA N T I N F O R M AT I O N /U P D AT I N G
INSTRUCTIONS
To be able to continue using the existing loose-leaf repair instructions, simply print the
following pages and insert them in the existing repair instructions:
15-18, 20-28, 32, 35, 40-54, 64, 66-69, 73, 77, 79-81, 84-207, 219, 280-291,
314-319, 323, 378-387
Remove page (s)
Replace by page (s)
Insert page (s)
2-1C to 2-3C
2-1D to 2-3D
2-5C to 2-11C
2-6D to 2-13D
3-3
3-3D
4-1A
4-1D
4-5 to 4-16
4-5D to 4-17D
5-1A to 5-2A
5-1D to 5-2D
5-12
5-12D
5-14B to 5-17
5-14D to 5-17D
5-21 / 5-25
5-21D / 5-25D
6-1A to 6-2
6-1D to 6-2D
6-5C to 6-19C
6-5D to 6-21D
7-1 to 7-49C
7-1D to 7-51D
8-1C to 8-37C
8-1D to 8-49D
9-1
9-1D
10-1.1C
10-2D
10-62D to 10-72D
11-1C
11-1D
11-22D to 11-27D
12-2C
12-2D
12-57D to 12-66D
after page
2-5D
KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided
for this purpose on the outside of the binder.
– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page.
Example: page no. 3-5
3 = chapter 3
5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the
index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience.
The respective headings can be entered in the list of contents.
E X P L A N AT I O N - U P D AT I N G
3.205.49-E
Repair Manual LC4
6/1998
Basicversion Modelyear 1998
(Engine number with first digit „8“)
3.205.73-E
Updating of Rep.Manual LC4
7/1999
Modelyear 1999
(Engine number with first digit „9“)
Art.-Nr. 3.206.006 -E
3.205.89-E
Updating of Rep.Manual LC4
9/2000
Modelyear 2000/2001
(Engine number with first digit „0“ and „1“)
3.210.30-E
Updating of Rep.Manual LC4
12/2001
Modelljahr 2002
(Engine number with first digit „2“)
3.206.006-E Updating of Rep.Manual LC4
4/2003
Repair manual KTM LC4
Modelljahr 2003
(Engine number with first digit „3“)
Modification / Updating:
Special tools, hydraulic clutch, Keihin carburator,
technical details model 2003, technical specification,
Maintenance schedule and wiring diagrams for modell 2003
Edition 4/2003
INTRODUCTION
This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the
latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working modes common in work shops has not been included. Safety rules
common in the work shop have also not been listed. We take it for granted that the repairs are
made by qualified profesionally trained mechanics.
Read through the repair manual before beginning with the repair work.
WARNING
STRICT COMPLIANCE WITH THESE INSTRUCTIONS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!
CAUTION
IS
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD
TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER
MOTORCYCLES UNFIT FOR TRAFFIC !
„NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS when replacing parts.
The KTM high performance engine is only able to meet user expectations if the maintenance work
is performed regularly and professionally.
KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an
ongoing total reengineered quality plan for a brighter tomorrow.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA
All rights reserved
REPLY FAX FOR REPAIR MANUALS
We have made every effort to make our repair manuals as accurate as possible but it is always possible for
a mistake or two to creep in.
To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us
as follows:
If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or
incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed
form to us at 0043/7742/6000/5349.
NOTE to table:
Enter the complete item no. for the repair manual in column 1 (e.g.: 3.210.66-E).
You will find the number on the cover page or in the left margin on each right page of the manual.
–
–
Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2.
–
Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective
passage of the text. If your text deviates from the text contained in the repair manual, please write
your text in German or English if possible.
–
Enter the correct text in column 4.
Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual
Page
Current text
Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman
Company/work shop
2-1D
2
GENERAL INFORMATION
INDEX
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
MODELS WITHOUT FRAME OIL
CHANGING THE ENGINE OIL . . . . .
CHANGING THE OIL FILTER . . . . . .
CHANGING THE MICROFILTER . . .
OIL CIRCUIT . . . . . . . . . . . . . . . . .
OIL CIRCUIT 660 SMC . . . . . . . . . .
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.2-2
.2-2
.2-3
.2-4
.2-5
MODELS WITH FRAME OIL
CHANGING THE ENGINE OIL . . . . . .
CHANGING THE FINE SCREEN FILTER
CHANGING THE OIL FILTER . . . . . . .
OIL CIRCUIT . . . . . . . . . . . . . . . . . .
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.2-6
.2-6
.2-7
.2-8
SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
EPC-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .2-13
2-2D
up to Modell 2001
from Modell 2002 on
A
A
1
Changing the engine oil (models without frame oil)
NOTE: The engine oil change is to be carried out when the engine is
still warm.
WARNING
AN
ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT
DO NOT BURN YOURSELF.
-
– Place the motorbike on a horizontal surface. Remove the two plugs
(1 and 2), and drain oil into a container.
NOTE: A third plug was installed in the 660 SMC model. Tightening
torque: 20 Nm
1
2
2
!
THE
SCREW PLUG
CAUTION
!
A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE.
– Clean the plugs thoroughly with a fireproof solvent and compressed
air, in order to remove the metal abrasion.
– After all the oil has drained through, clean raised and flat faces and
install plugs with seals. Tighten plug 1 with 30 Nm (22 ft.lb) and
plug 2 with 20 Nm (15ft.lb).
– Remove the oil dipstick at the clutch cover, pour in engine oil and
replace the oil dipstick.
Oil capacity (up to model 2002) : 1.40 l
Oil capacity (from model 2003 on) : 1.50 l
Changing the oil filter
Replace the oil filter when changing the engine oil.
– Press the foot brake pedal and place a screwdriver or similar between
foot brake pedal and stopper roll so that the oil filter cover is more
accessible.
– Remove banjo bolt 3 and the three bolts 4.
– Remove oil filter cover 5 and oil filter.
– Clean filter housing, oil filter cover and sealing surfaces. Check oil
duct in oil filter cover if clogged.
Art.-Nr. 3.206.006 -E
5
3
4
– Press the new O-ring 6 into the groove of the filter cover (if
necessary fix with grease). Mount a new oil filter 7 on the
connection piece of the oil filter cover an mount the whole unit.
3
5
NOTE: From model 2001 onwards the gasket 8 is mounted with a
changed filter cover 5. If the new gasket 8 should be used on older
engines, the filter cover must be flat regrinded or renewed (see
Technical Info Nr. 0201/30/01).
6
Repair manual KTM LC4
4
8
7
– Mount three bolts and tighten with 5 Nm (4 ft.lb).
– Mount hollow bolt with seal rings and tighten with 15 Nm
(11 ft.lb).
2-3D
Changing the microfilter
1
2
Replace the microfilter while changing the engine oil.
– To do so, remove bolts 1 and take off the microfilter cover 2.
– Remove the microfilter, clean its parts and check the O-ring on the
microfilter cover for signs of damage.
– Insert a new microfilter into the filter housing, tilt the motorcycle
sideways and fill the microfilter housing with engine oil.
– Slightly grease the O-ring and mount the microfilter cover. Then put
the motorcycle back on its stand.
1
– It is necessary to bleed the microfilter so that all lubricating points
can be quickly supplied with engine oil.
– To do this, fill with oil and remove the jet screw from the oil line on
the clutch cover.
– Start the engine and close off the bore on the clutch cover with a
rag.
– Allow the engine to run at idle until oil runs out of the oil line 3.
– Turn off the engine. Mount the jet screw, using two new seal rings.
– Torque the jet screw to 10 Nm and check for leaks.
3
– Start the engine and let it idle for 1 - 2 minutes.
!
CAUTION
!
DO
NOT REV UP THE ENGINE IMMEDIATELY AFTER AN OIL CHANGE ! KEEP IN MIND
THAT IT TAKES SOME TIME UNTIL ALL LUBRICATING POINTS ARE PROPERLY PROVIDED
WITH ENGINE OIL.
JASO T903 MA
TEMPERATURE
0°C
32°F
5W/40
10W/50
– Allow the engine to run until warm. Then, turn off the engine, and
place the motorbike on a flat, level surface in an upright position
(center stand). Wait for 5 minutes. Unscrew and remove the oil
dipstick, and wipe it clean with a cloth.
– Screw the dipstick in all the way and remove it again. The oil level
should be between the two marks on the oil dipstick, however, it
must never rise above the MAX mark. Otherwise, engine oil would
get into the air filter box by way of the engine venting system. Add
engine oil, if necessary.
– Finally, check oil system and engine for leaks.
!
CAUTION
!
– ONLY
–
–
USE HIGH-QUALITY OILS MEETING OR SURPASSING THE QUALITY
REQUIREMENTS OF JASO T903 MA (FOR SPECIFICATIONS SEE CONTAINERS).
INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE
ENGINE.
YOU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE
CRITERIA.
NOTE: Dispose of used oil properly !
Under no circumstances may used oil be disposed of in the sewage
system or in the open countryside.
1 liter oil contaminates 1.000.000 liter water.
2-4D
Oil circuit
The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil filter 3. After the oil filter, an oil lead branches
off to a jet 4 which sprays engine oil onto the piston pin bearing and piston head. The second oil lead takes the main flow of oil
to the microfilter 5, which filters out even the finest impurities. The cleaned engine oil is pumped through the oil lead and the
clutch cover into the crankshaft to the connecting rod bearing 6 and drips into the crankcase. An additional oil pump 7 sucks
the engine oil out of the crankcase and pumps it through the oil line 8 to the gear wheels of the 4th and 5th gear. Via the gear
wheels, the engine oil reaches the oil sump. The timing chain 9 runs through the oil sump and transports the engine oil upwards
to the cylinder head. Through the bore bk the oil reaches the camshaft bl and the valves.
10
11
9
4
Art.-Nr. 3.206.006 -E
6
7
8
3
1
Repair manual KTM LC4
2
5
2-5D
Oil circuit 660 SMC
The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil filter 3. After the oil filter, an oil lead branches
off to a jet 4 which sprays engine oil onto the piston pin bearing and piston head. The second oil lead takes the main flow of oil
to the second jet 4 and the microfilter 5, which filters out even the finest impurities. The cleaned engine oil is pumped through
the oil lead and the clutch cover into the crankshaft to the connecting rod bearing 6 and drips into the crankcase. An additional
oil pump 7 sucks the engine oil out of the crankcase and pumps it through the oil line 8 to the gear wheels of the 4th and 5th
gear. Via the gear wheels, the engine oil reaches the oil sump. The timing chain 9 runs through the oil sump and transports the
engine oil upwards to the cylinder head. Through the bore bk the oil reaches the camshaft bl and the valves.
10
11
9
6
4
4
7
8
3
1
2
5
2-6D
Changing the engine oil (models with frame oil)
NOTE: For improved cooling of the engine oil, the front tube of the
frame was integrated into the oil circuit.Thus, when you change the oil,
you also have to drain the engine oil from the front tube and bleed the
oil system.
If the oil system is not bled at all or bled insufficiently, the bearings of
the engine will not get enough lubrication, which in turn may result in
engine failure.
The engine oil change is to be carried out when the engine is still warm.
WARNING
AN
ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT
DO NOT BURN YOURSELF.
up to Modell 2001
from Modell 2002 on
A
A
1
-
– Place the motorcycle on a horizontal surface. When working on a
motorcycle with engine guard, remove the latter before commencing
to change the engine oil.
– Remove the two plugs 1 and 2, and drain oil into a container.
!
PLUG A
CAUTION
!
MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE.
1
2
2
Changing the fine screen filter
Replace the fine screen 3 filter when changing the engine oil.
– Loosen the three bolts and remove the cover.
– Undo the spin-on filter 3 with the corresponding special tool, twist
it off manually and let the engine oil out of the front pipe of the
frame.
Art.-Nr. 3.206.006 -E
4
– Unscrew plug 4 at the lower end of the front pipe and drain oil (up
to model 2000).
3
6
– Clean sealing surfaces on the front pipe 5, fill new fine screen filter
with engine oil, and oil rubber gasket 6. Replace fine screen filter
and screw it back in place, your bare hand will do.
!
USE
CAUTION
USING
ONLY ORIGINAL KTM FINE SCREEN FILTERS.
RESULT IN DAMAGE TO THE ENGINE!
Repair manual KTM LC4
5
!
ANOTHER FILTER BRAND CAN
– From model 2001 onwards the drain plug 7 of the frame oil is
located in the oil filter flange, draining is only possible after removing
the oil filter.
7
– Clean all 3 plugs thoroughly with a fireproof solvent and compressed
air, in order to remove the metal abrasion.
– After all the oil has drained through, clean sealing areas and install
plugs with gaskets. Tighten plug 1 with 30 Nm (23 ft.lb), plug 2
with 20 Nm and plug 4 with 10 Nm (up to model 2000). Drain plug
of frame oil (model 2001 onwards) is to be mounted without a
gasket and tightened to 10 Nm (7 lb.ft).
2-7D
Changing the oil filter
Replace the oil filter when changing the engine oil.
– Press the foot brake pedal and place a screwdriver or similar between
foot brake pedal and stopper roll so that the oil filter cover is more
accessible.
– Remove banjo bolt 1 and the three bolts 2.
– Remove oil filter cover 3 and oil filter.
– Clean filter housing, oil filter cover and sealing surfaces. Check oil
duct in oil filter cover if clogged.
3
1
2
– Press the new O-ring 4 into the groove of the filter cover (if
necessary fix with grease). Mount a new oil filter 5 on the
connection piece of the oil filter cover an mount the whole unit.
1
3
NOTE: From model 2001 onwards the gasket 6 is mounted with a
changed filter cover 3. If the new gasket 6 should be used on older
engines, the filter cover must be flat regrinded or renewed (see
Technical Info Nr. 0201/30/01).
4
2
6
5
– Mount three bolts and tighten with 5 Nm (4 ft.lb).
– Mount banjo bolt with seal rings and tighten with 15 Nm
(11 ft.lb).
– Remove the oil dipstick at the clutch cover, pour in engine oil and
replace the oil dipstick.
Oil quantity (engine only) : 1.40 liter
!
CAUTION
!
IF
THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME, YOU
MUST BLEED THE OIL SYSTEM!
– Remove the plug 7 next to the steering head and use a lubricating
syringe 8 (see special tools) to fill the front pipe with approx. 0.6 l
engine oil. Add oil until it begins to emerge at bore B.
– Mount the plug, using a new seal ring.
!
CAUTION
!
DO
NOT REV UP THE ENGINE IMMEDIATELY AFTER AN OIL CHANGE. KEEP IN MIND
THAT IT TAKES SOME TIME UNTIL ALL LUBRICATING POINTS ARE PROPERLY PROVIDED
WITH ENGINE OIL.
7
B
– Allow the engine to run until warm. Then, turn off the engine, and
place the motorbike on a flat, level surface in an upright position
(center stand). Wait for 5 minutes. Unscrew and remove the oil
dipstick, and wipe it clean with a cloth.
– Screw the dipstick in all the way and remove it again. The oil level
should be between the two marks on the oil dipstick, however, it
must never rise above the MAX mark. Otherwise, engine oil would
get into the air filter box by way of the engine venting system. Add
engine oil, if necessary.
– Finally, check oil system and engine for leaks.
!
CAUTION
!
– ONLY
–
–
8
USE HIGH-QUALITY OILS MEETING OR SURPASSING THE QUALITY
REQUIREMENTS OF JASO T903 MA (FOR SPECIFICATIONS SEE CONTAINERS).
INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE
ENGINE.
YOU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE
CRITERIA.
NOTE: Dispose of used oil properly !
Under no circumstances may used oil be disposed of in the sewage
system or in the open countryside !
1 liter oil contaminates 1.000.000 liter water !
2-8D
Oil circuit
The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil filter 3. After the oil filter, an oil line branches off
to a jet 4 which sprays engine oil onto the piston pin bearing and piston head. The second oil line takes the main flow of oil into
the front pipe of the frame 5, where the engine oil is cooled down. Afterwards the engine oil runs through the fine screen filter
6, which filters out even the finest impurities. The cleaned engine oil is pumped through the oil line and the clutch cover into the
crankshaft to the conrod bearing 7 and drips into the crankcase. An additional oil pump 8 sucks the engine oil out of the
crankcase and pumps it through the oil line 9 to the gear wheels of the 4th and 5th gear. Via the gear wheels, the engine oil
reaches the oil sump. The timing chain bk runs through the oil sump and transports the engine oil upwards to the cylinder head.
Through the bore hole bl the oil reaches the camshaft bm and the valves.
11
12
5
Art.-Nr. 3.206.006 -E
10
4
Drain plug - frame oil
up to Model 2000
7
6
8
3
Repair manual KTM LC4
1
2
Drain plug - frame oil
Model 2001 onwards
9
2-9D
Functional characteristics of the secondary air system (SLS)
When the exhaust valve is open, the hot exhaust gases flow through the exhaust port 1 at a very high speed. As a consequence
of the flow conditions in the exhaust port and due to the influence exerted by the entire exhaust system on the escaping gases,
the pressure in the exhaust port drops temporarily (underpressure).
During these cyclic underpressure phases, the secondary air valve 2 opens, thus adding oxygen of the air to the hot exhaust
gases through pipe 3.
At higher engine speeds, the secondary air valve interrupts the oxygen supply to prevent overheating of the catalytic converter.
Additionally, the secondary air valve prevents the exhaust gases from flowing back into the air filter box 4.
When the motorcycle is pushed (high underpressure in the intake port) the control valve (ASV) 5 interrupts the air flow into the
exhaust port to prevent exhaust detonations.
The control valve is controlled via a control pipe 6. This control pipe transmits the underpressure from the intake port 7 to the
control valve.
During normal operation (slight underpressure in the intake port), the control valve is open.
The reaction between the oxygen of the air and the harmful components of the exhaust gases (CO - carbon monoxide, HC hydrocarbon) reduces the content of harmful substances by approximately 50%. The use of a catalytic converter, in combination
with the SLS, allows an additional significant reduction of pollutant emissions.
6
3
5
4
2
1
7
2-10D
Electronic Power Control System (EPC)
Main components of the EPC system:
–
–
–
–
–
Constant-pressure carburetor
Control device
Solenoid valve
2 contact screws at the engine
Micro-switch (at carburetor)
Art.-Nr. 3.206.006 -E
FUNCTIONAL CHARACTERISTICS:
The EPC system is not activated during normal operation of the motorcycle.
It is, however, activated as soon as the throttle is fully opened at a speed of 45 - 55 km/h while the second or third gear are
engaged.
The EPC control device opens the solenoid valve, directing an appropriate flow of fresh air onto the upper side of the slide
membrane of the constant-pressure carburetor, thus reducing the opening speed of the slide. This mechanism significantly reduces
the exhaust gas emissions of the vehicle.
Repair manual KTM LC4
SOLENOID VALVE
2-11D
SPECIAL TOOLS
39
6
26
11
12
8
64
1215
16
Silicone Liquid Gasket
Silicone Flüssige Dichtung
1
23
4#
4
5#
5
5
27
7
150
10
3
49
14
70
19
9
2
17
8
22
8#
130
15
48
65
ThreeBond
20
35
18
2-12D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
FIG.
1
2
3
4
4#
5
5#
6
7
8
8#
9
10
11
12
14
15
16
16
17
18
19
19
20
22
23
26
39
48
49
PART NO.
560.12.001.000
583.29.003.000
580.12.005.025
584.29.009.000
580.12.009.000
510.12.016.000
584.29.031.000
580.12.015.089
580.12.015.095
580.12.015.100
580.12.015.101
585.29.015.102
590.29.021.044
580.12.019.000
590.29.019.000
6.276.470
590.29.041.000
6.899.785
584.29.059.000
590.29.034.000
151.12.017.000
151.12.018.000
151.12.018.100
584.29.012.000
3090.98
584.29.037.040
584.29.037.043
580.30.080.000
510.12.012.000
546.29.027.000
580.29.026.007
583.29.039.000
584.29.048.000
503.29.050.000
DESCRIPTION
Universal engine work stand
Clutch holder
Mounting sleeve for crankshaft seal ring Ø 25 mm
Magneto extractor (Kokusan)
Magneto extractor (SEM)
Protection cover for crankshaft (SEM)
Protection cover for crankshaft (Kokusan)
Piston ringspanner Ø 89 mm
Piston ringspanner Ø 95 mm
Piston ringspanner Ø 100 mm
Piston ringspanner Ø 101 mm
Piston ringspanner Ø 102 mm
Extractor for primary gear and clutch hub
Valve mounting set
Valve mounting set
Valve spring-push insert
Feeler gauge for valve clearance
Loctite 243 blue 6 ml
Loctite 648 red 20 ml
Wrench for mixture regulating screw
Gear puller
Internal bearing puller 12 - 16 mm
Internal bearing puller 18 - 23 mm
Flywheel holding spanner (Kokusan)
Seal (Three-Bond)
Mounting tool inner ring NJ207 (all versions of LC4)
Mounting tool inner ring NJ306 (LC4-E)
Crankshaft locking bolt
Chain sprocket holder
Clutch rivetting tool
Limit plug gauge Ø 7,05 mm
Oil filter wrench
Syringe for pipe oil
Bleeding syringe for hydraulic clutch
2-13D
2
Checking the oil level of the hydraulic clutch
1
To check the oil level in the master cylinder of the clutch remove the
cover. For this purpose, remove screws 1 and cover 2 together
with the rubber boot 3 . The oil level in the horizontal-standing
master cylinder should be 4 mm below the upper edge.
If necessary, fill up with biodegradable hydraulic oil SAE 10 (f.ex.
Motorex Kupplungs-Fluid 75).
!
3
CAUTION
!
– KTM
–
USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH
CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.
ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER
CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.
Bleeding of the hydraulic clutch
To bleed, the cover of the master cylinder of the clutch needs to be
removed. For this purpose, remove screws 1 and take off cover 2
together with rubber bellows 3. At the slave cylinder of the clutch,
remove the bleeder nipple 4. In its place, mount the bleeder syringe 5
which is filled with SAE 10 hydraulic oil. Refill oil until oil is discharged
from the bore 6 of the master cylinder in a bubble-free state. Make
sure that the oil does not overflow. The bleeder syringe can be
purchased from your KTM dealer.
5
4
6
Having completed the bleeding procedure, you have to verify that the
oil level in the master cylinder is correct. If necessary, fill up with
biodegradable hydraulic oil SAE 10 (f.ex. Motorex Kupplungs-Fluid
75).
CAUTION
!
!
– KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH
CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.
– ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER
CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.
3-1D
REMOVING AND REFITTING ENGINE
INDEX
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3
3-2D
Removing the engine
– Thoroughly clean the entire motorcycle.
– When working on a motorcycle with engine guard, remove the
latter.
– Jack the motorcycle up on a stable supporting device.
– Remove the seat, the side covers as well as the tank and the spoilers.
– Disconnect the negative pole of the battery.
– Undo the 2 hose clamps 1 as well as hose clamp 2. Pull the
carburetor backwards out of the intake flange and swing it aside.
2
1
Art.-Nr. 3.206.006 -E
– Unhook the 4 springs 3 at the exhaust manifold.
– Undo bolt 4.
3
4
Repair manual KTM LC4
– Undo bolt 5 and remove the exhaust manifold.
5
6
8
7
– Disconnect water hoses 6 and 7 from the water pump and let out
the cooling liquid.
– Remove the two bolts 8, disconnect and remove the fan.
– Unhook the clutch cable and the decompression cable.
– Disconnect the bleeder hose at the valve cover.
3-3D
– Remove the two bolts 1 and take off the chain guard.
– Remove the chain damping plate 6.
– Remove the chain joint and take off the chain.
2
1
1
From model 2003 on:
– Remove the 3 bolts 3 of the clutch slave cylinder and pull the clutch
slave cylinder off the casing.
3
3
4
– Disconnect the bleeder hose 4.
– Disconnect the positive cable 5 from the electric starter motor.
5
– Disconnect all electric plug and socket connections from the engine.
– Remove the banjo bolt 6.
6
– Disconnect the water hose 7.
7
3-4D
– Remove the jet screw 1.
– Remove the left as well as the right engine retaining bracket 2.
1
2
– Remove bolt 3 as well as the swingarm pivot 4.
– Then lift the engine out of the frame.
4
3
Installing the engine
Art.-Nr. 3.206.006 -E
NOTE: To install the engine reverse the procedure indicated above.
– When working on a model with an engine guard keep in mind that
opening A must be located on the right side and face the engine.
Tightening torques:
A
Swingarm pivot:
Engine mounting bolts M8:
Engine mounting bolts M10:
Banjo bolt (oil pipe on the frame):
Jet screw (clutch cover):
All other M6 bolts:
All other M8 bolts:
All other M10 bolts:
100
40
70
15
10
10
25
45
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
74
30
50
11
7
7
19
33
ft.lb
ft.lb
ft.lb
ft.lb
ft.lb
ft.lb
ft.lb
ft.lb
NOTE: Use only high-quality antifreeze (e.g. Shell Advance Coolant) for
the cooling system. The frame oil should always be changed after
engine repair.
!
CAUTION
!
Repair manual KTM LC4
AFTER
INSTALLING THE ENGINE CAREFULLY BLEED THE OIL SYSTEM (SEE OIL CHANGE
INSTRUCTIONS). DO NOT REV THE ENGINE DURING THE BLEEDING PROCESS !
– The motorcycle can be tested as soon as the engine is running
smoothly. After the test run check and, if necessary, correct all liquid
levels.
4-1D
DISASSEMBLING THE ENGINE
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
INDEX
DRAIN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
REMOVING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .4-2
REMOVING THE CLUTCH RELEASE LEVER AND THE OIL HOSES . . . . . . .4-3
REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE EPC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE IGNITION (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE ELECTRIC STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . .4-6
REMOVING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . . . . . . . .4-7
BLOCKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
REMOVING THE CAMSHAFT AND THE AUTOMATIC TENSIONER . . . . . .4-8
REMOVING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
REMOVING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . .4-11
REMOVING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
REMOVING THE TIMING CHAIN AND THE TIMING GEAR . . . . . . . . . . .4-14
REMOVING THE CLUTCH RELEASE SHAFT . . . . . . . . . . . . . . . . . . . . . . .4-14
PARTING OF ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
REMOVING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
REMOVING THE TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . . . .4-17
REMOVING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4
4-2D
– Fit engine to engine work stand.
– Remove bolt 1 together with the washers. Then remove the shift
lever together with the V-seal ring behind.
– Remove bolt 2 together with the washer. Then remove the
kickstarter.
1
2
Art.-Nr. 3.206.006 -E
– Remove spark plug
up to model 2001
from modell 2002 on
Drain engine oil
– Remove oil drain plug 3 and magnetic plug 4 and drain oil.
Repair manual KTM LC4
3
4
3
4
Removing the electric starter motor
5
– Undo 2 bolts 5 and remove the electric starter motor from the
flange.
4-3D
Removing the clutch release lever and the oil hoses
– Undo bolt 1 and remove the clutch release lever.
1
– Remove the two banjo bolts 2 together with the seal rings and
remove both oil hoses.
2
2
Removing the oil filter
– Remove all three bolts 3 and take off the oil filter cover together
with the O-ring or gasket.
– Take the oil filter out of the engine housing.
3
Removing the EPC wiring harness
4
– Undo the 3 bolts 4 and remove the EPC wiring harness.
4
Removing the ignition (Kokusan 4K-2)
– Undo 4 bolts and remove the ignition cover with the stator incl.
gasket.
4-4D
– Undo 6 bolts and remove starter flange incl. gasket.
– Insert the holding spanner 2 into the 2 bores of the flywheel.
– Hold the flywheel and remove the hexagon nut (LH thread).
– Remove the disc.
!
2
CAUTION
!
TO
AVOID DISTORTION OF THE CRANK WEB, NEVER MOUNT THE CRANKSHAFT
LOCKING BOLT TO STEADY THE FLYWHEEL.
Art.-Nr. 3.206.006 -E
– Put the protection cover 1 onto the crankshaft and mount the
flywheel extractor.
1
– Pull off the flywheel and take the woodruff key out of the
crankshaft.
!
CAUTION
!
Repair manual KTM LC4
NEVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID
LOOSENING OF THE MAGNETS.
4-5D
Removing the ignition (SEM)
– Undo the 4 bolts and remove ignition cover and O-ring.
– Use the crankshaft locking bolt to block the crankshaft.
–
–
–
–
Unscrew collar nut (LH thread) and remove spring disc.
Fit extractor and pull off flywheel. Use protective sleeve.
Remove woodruff key from the crankshaft.
Twist the crankshaft locking bolt out until the crankshaft is no longer
blocked.
!
CAUTION
!
NEVER
USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID
LOOSENING OF THE MAGNETS.
Removing the ignition (Kokusan 4K-3)
– Undo the 4 bolts and take off the ignition cover together with the
O-ring.
– Use the crankshaft locking bolt to block the crankshaft.
– Undo the collar nut (LH thread) and remove the spring washer.
– Mount the extractor and pull off the flywheel.
– Take the woodruff key out of the crankshaft.
– Finally, twist out the crankshaft locking bolt until the crankshaft is no
longer blocked.
!
NEVER
CAUTION
!
USE A HAMMER OR SIMILAR TOOL ON THE FLYWHEEL TO PREVENT
LOOSENING OF THE MAGNETS.
4-6D
1
Removing the electric starter drive
2
– Pull the reduction gear 1 off the bearing bolt.
– Remove both needle bearings 2 and pull the bearing bolt 3 out of
the engine housing.
3
– Remove the freewheel gear 4 and the needle bearing 5.
5
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
4
4-7D
Removing the cylinder head top section
– Unscrew plug 1 with gasket and remove pressure spring from
automatic tensioner.
1
– Undo the 4 hose clamps and remove both hoses (2 and 3).
2
3
– Remove all 6 bolts 4 together with the seal rings and take off both
valve covers together with the gaskets.
4
– Remove the hexagon nut 5 and take off the retaining bracket of the
solenoid valve 6.
NOTE: A retaining bracket is only used in engines with EPC.
6
5
– Remove all 11 bolts. Then remove the cylinder head top section.
!
WHEN
CAUTION
!
REMOVING CYLINDER HEAD TOP SECTION DO NOT CHOCK IT.
DAMAGE THE HOUSING OF THE WATER PUMP.
THIS
WOULD
NOTE: The control valve of SLS models can be removed after undoing
the bolts of the cylinder head top section.
4-8D
– Pull water pump upward and simultaneously turn crankshaft.
NOTE: When groove A in the HH bolt is vertical, the water pump can
be pulled upward and taken out of the cylinder head without the
application of force.
A
Blocking the crankshaft
– Turn the piston to position TDC (mark B must coincide with the
plane surface of the cylinder head).
B
– Undo the crankshaft locking bolt 1.
– Remove the copper disc 2.
2
Art.-Nr. 3.206.006 -E
1
NOTE: Same engines are equipped with a normal bolt M8x16 and a
copper washer 8x12x1 instead of the crankshaft locking bolt M8 and a
copper washer 8x14x3. In this case the special tool 580.30.080.000
must be used.
– Reinsert crankshaft locking bolt by hand.
– If the bolt does not slide smoothly into its bore, slightly move the
camshaft gear (if cylinder head top section is mounted turn the
flywheel) back and forth until the crankshaft locking bolt engages in
its bore.
– Tighten crankshaft locking bolt with 20 Nm.
!
UNDER
CAUTION
bolt
NO CIRCUMSTANCES APPLY FORCE TO
AS THIS WILL DAMAGE THE CRANKSHAFT.
!
IN CRANKSHAFT LOCKING BOLT
Removing the camshaft and the automatic tensioner
– Remove the driving bolt 3 together with the two washers.
Repair manual KTM LC4
3
6
4
5
– Remove the two bolt 4 and take off the automatic tensioner 5 and
the clamp 6.
4-9D
– Using a screwdriver, lever circlip 1 out of the groove.
1
– Tilt camshaft and remove needle bushing 2.
2
– While tilted, pull camshaft from camshaft gear and remove together
with grooved ball bearing and circlip.
– Take the camshaft gear out of the timing chain as indicated in the
illustration.
4-10D
1
Removing cylinder head
– Unscrew chain guide bolt 1 incl. gasket, bolts 2 and collar nuts 3.
3
2
– Unscrew the 4 collar bolts 4 and detach cylinder head with gasket.
4
Removing cylinder and piston
Art.-Nr. 3.206.006 -E
– Unscrew the 4 collar nuts at the cylinder base 5.
– Remove cylinder and cylinder base gasket.
5
Repair manual KTM LC4
6
– When working on an engine with a microfilter, remove the AH bolt
6 before taking off the cylinder.
– Disconnect the oil hose at the clutch cover and remove the
microfilter together with the holder.
4-11D
– Remove two wire circlips and press piston pin out of piston.
– Remove piston.
Removing engine sprocket
– Remove collar bolt 1 and spring washer.
– Remove the sprocket from the counteshaft.
– Remove the distance bushing from the countershaft.
1
NOTE: If the gear-box and the clutch of the engine are in good
condition, throw it into gear in order to block the take-off shaft
(frictional connection to the blocked crankshaft is present). If the takeoff shaft cannot be blocked as described above, a chain sprocket holder
must be applied for the removal of the chain sprocket nut.
Removing clutch and primary drive
– Remove the 11 bolts and detach clutch cover with gasket.
– Unscrew the bolts 3 of the clutch crosswise to prevent the clutch
discs from jamming when the springs are relieved of tension.
– Remove bolts, spring retainer and springs.
– Remove pressure cap with push rod.
3
– Remove the disc package and take the O-ring 2 also off the inner
clutch hub.
2
4-12D
– Release the lock washer of the inner clutch hub.
– Put the clutch holder 1 onto the inner clutch hub and undo the
hexagon nut (see illustration).
– Remove the clutch holder.
– Take the hexagon nut, the lock washer and the inner clutch hub off
the main shaft.
1
– Try to turn the outer clutch hub in both directions to check the
absorbing elements. Dead travel in either direction is inadmissible.
Art.-Nr. 3.206.006 -E
– Take the outer clutch hub and the needle bearing 2 off the main
shaft.
2
– Remove the kickstarter intermediate gear 3.
Repair manual KTM LC4
3
– Unscrew hexagon nut of primary gear wheel and detach spring
washer from the crankshaft.
– Fit extractor for primary gear and pull off primary gear.
4-13D
– Remove the balancer shaft from the bearing by hand.
Removing the oil pumps
3
1
NOTE: The following procedure must always be performed on both oil
pumps.
– Remove the locking washer 1.
– Remove stop disc 2 and the oil pump gear 3.
2
– Remove the needle roll 4 and stop disc 5.
4
5
– Twist out the 6 bolts 6 and remove the oil pumps from the housing.
NOTE: For better access to bolt 7 remove bolts 8 and take off the
retaining bracket.
7
8
6
4-14D
2
1
Removing the timing chain and the timing gear
– Remove allan head bolt 1 and remove timing chain guide from the
casing.
– Unscrew flat-head screw 2 and remove timing chain tensioner.
– Unscrew allan head bolt 3 and remove timing chain securing guide.
– Insert timing chain into the clutch compartment of the engine
housing and disengage from timing gear.
3
– Remove the primary gear woodruff key 4 from the crankshaft.
– Withdraw the timing pinion from crankshaft with a 2-jaw puller.
– Take the woodruff key of the timing gear out of the crankshaft.
4
Removing the clutch release shaft
Art.-Nr. 3.206.006 -E
– Remove bolt(s) 5 and take off the retaining bracket 6.
5
6
Repair manual KTM LC4
7
8
– Pull the clutch release shaft 7 out of the housing.
– Remove the grooved ring 8.
4-15D
Parting of engine housing
–
–
–
–
Loosen the crankshaft locking bolt.
Tip ignition side upwards and remove all the housing bolts.
Release engine mount on engine repair stand.
Lift right hand housing half with suitable tools bearing on the bosses
provided, or part with a few light plastic mallet blows against the
counter shaft.
!
CAUTION
!
LEVERING
APART WITH A SCREW-DRIVER OR SIMILAR TOOL MUST BE AVOIDED, SINCE
THE SEALING SURFACES ARE EASILY DAMAGED.
– Remove housing-half and gasket.
1
– Take the stop disc 1 off the main shaft (can stick to the inside of the
housing).
– Take the O-ring 2 off the countershaft.
– Remove the crankshaft from the bearing by hand.
2
– Take the inner ring 3 of the roller bearing and the O-ring below 4
off the countershaft.
3
4
Removing the shift mechanism
– Push back slide plate 5 and pull shift shaft out of the kickstarter
shaft.
– Remove allan head bolt 6 and detach locking piece.
6
5
4-16D
– Remove the 3 bolts 1 and detach the shift mechanism support 2.
2
1
1
3
4
– Pull out the shift rails 3 and swing the shift forks aside, taking care
of the shift rolls 6 on the driving pins of the shift forks.
– Pull the shift roller 4 out of the bearing seat.
3
5
Art.-Nr. 3.206.006 -E
NOTE: Although the counter shaft shift forks are identical they should
be refitted in the same position as before if reused. Therefore mark
accordingly upon removal.
6
Repair manual KTM LC4
– Take the shift forks 5 together with the shift rolls 6 out of the
engine housing.
4-17D
Removing the transmission shafts
– Pull both transmission shafts out of the bearing seats.
– Take the 3rd gear/sliding gear and the 1st gear/idler gear out of the
engine housing together with the needle bearing and the stop disc.
NOTE: A roller bearing was installed in the 660 SMC model, thus a stop
disc is unnecessary.
Removing the kickstarter shaft
– Put kickstarter onto kickstarter shaft and hold in this position.
– Unscrew stop bolt 1 and relieve starter spring tension by releasing
the kickstarter.
1
– Remove kickstarter shaft assembly from housing.
– Take the starter gear out of the housing bag together with the
needle bearing and the stop discs.
– Clean all parts and check for wear, replace if necessary.
NOTE: When an engine is completely overhauled it is recommended
that all gaskets, shaft seal rings, O-rings and, possibly, all bearings are
renewed.
5-1D
SERVICING ON INDIVIDUAL COMPONENTS
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
INDEX
WORKING ON THE RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . .5-3
WORKING ON THE LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . .5-5
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
MEASURING AND ADJUSTING OF CRANKSHAFT AXIAL PLAY . . . . . . . . .5-7
CHECKING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
MOUNTING INSTRUCTIONS FOR PISTON RINGS . . . . . . . . . . . . . . . . . . .5-8
PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
MEASURING PISTON AND CYLINDER, DETERMINING
THE PISTON FITTING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
CYLINDER – NIKASIL COATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
RECOATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
DISASSEMBLING THE CYLINDER HEAD AND CHECKING
THE COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
DISASSEMBLING THE CYLINDER HEAD TOP SECTION AND
CHECKING COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . .5-11
PRE-ASSEMBLING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . .5-11
CHECKING THE COMPONENTS OF THE TIMING MECHANISM FOR WEAR . . .5-12
DISASSEMBLING THE CAMSHAFT AND CHECKING THE
COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
PRE-ASSEMBLING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
PREASSEMBLY OF AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . .5-13
DISASSEMBLING THE OIL PUMPS AND CHECKING THE
COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
OIL LINES (SX, SXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
OIL LINES (SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
OIL LINES (660 SMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
OIL LINES (MODELS WITH FRAME OIL) . . . . . . . . . . . . . . . . . . . . . . . . .5-15
CHECKING THE KICKSTARTER COMPONENTS FOR WEAR . . . . . . . . . . .5-16
PREASSEMBLY OF KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .5-16
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
REPLACING ABSORBING ELEMENTS OF THE OUTER CLUTCH HUB . . . .5-16
5
5-2D
INDEX
CHECKING THE CLUTCH COMPONENTS FOR WEAR . . . . . . . . .
CHECKING THE SHIFT MECHANISM COMPONENTS FOR WEAR .
PREASSEMBLY OF SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT MECHANISM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING AND REASSEMBLING THE WATER PUMP . . . . .
IMPORTANT NOTE REGARDS WORKING ON TRANSMISSION . .
ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE COUNTER SHAFT . . . . . . . . . . . . . . . . . . . . .
REMOVING THE INTERMEDIATE GEAR . . . . . . . . . . . . . . . . . . .
CHECKING THE FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FREEWHEEL HUB . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STATOR AND THE PULSE GENERATOR (KOKUSAN 4K-2)
REPLACING THE STATOR (KOKUSAN 4K-2)
IGNITION (SEM) . . . . . . . . . . . . . . . . . . .
CHECKING THE STATOR (SEM) . . . . . . . . .
REPLACING THE STATOR (SEM) . . . . . . . .
CHECKING THE STATOR (KOKUSAN 4K-3)
REPLACING THE STATOR (KOKUSAN 4K-3)
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.5-25
IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING
Read through the following section before commencing work. Then determine the assembly sequence so
that the engine housing halves only need to be heated up once before replacing the bearings.
Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows,
the housing halves must be placed on a suitably large plane surface, supporting the whole of the sealing
surface without damaging it. A wooden panel is best used as a base.
Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available,
use a suitable mandrel and hammer them in with great care. Cold bearings will practically drop into
their seats at an engine housing temperature of approx. 150° C.
After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In
that event the housing must be replaced.
5-3D
Working on the right housing half
Remove shaft seal rings and heat housing half to approx. 150° C by
means of a hot-plate.
Roller bearing of crankshaft 1
Proceed as for left housing half.
4
5
3
3
Cylinder roller bearing of counter shaft 2
Remove shaft seal ring. Press old bearing inwards. Press in new bearing
from inside as far as stop.
Oil ducts 3
Use compressed air to clean all oil ducts. Ensure that the oil ducts are
not clogged.
Counter shaft seal ring 4
Press in new shaft seal ring from outside until flush.
Crankshaft seal ring 8
Press in new shaft seal ring from outside until flush.
NOTE: Engine with an electric starter have a stop disk instead of the
shaft seal ring 5. Do not remove this disk.
6
Art.-Nr. 3.206.006 -E
1
2
8
Repair manual KTM LC4
Needle bearing of main shaft 6
Pull old bearing from bearing seat using bearing extracto and insert. In
order to apply the bearing extractor in an vertical position, a steel plate
(see special tools) must be laid on the sealing area of the housing. The
bearing extractor jaws should fit as close as possible up to the housing
walls. Then press in new bearing from inside until flush.
6
Oil nozzle 7
For the cleaning of the oil nozzle and the oil duct simply blow it
through with compressed air from the nozzle side. If the oil nozzle is
disassembled, secure it with Loctite 243 when mounting again.
Then check the lubrication bore A of the crankshaft roller bearing for
free passage.
7
After the case half has cooled down, check bearings for secure fit.
A
5-4D
Needle bushes of the clutch disengagement
– Pull out the needle bushes of the clutch disengagement with a gear
puller and insert from the housing half.
– Oil the needle bushes.
– Press the first needle bush A to stop.
– Press the second needle bush B so that it is flush.
B
A
5-5D
Working on the left half of the housing
5
4
1
Remove shaft seal rings and heat housing half to approx. 150° C by
means of a hot-plate.
Needle bearing of counter shaft 1
Press in new needle bearing from inside until flush.
Shaft seal ring of kickstarter shaft 2
Press in new shaft seal ring from outside with sealing lip facing inwards
until flush.
Grooved ball bearing of the balancer shaft 3.
Use an extractor and insert to remove the grooved ball bearing from
the housing half.
2
3
6
Shaft seal ring of crankshaft 4
Press in new shaft seal ring from outside with sealing lip facing inwards
until flush.
6
Retaining plate for main shaft grooved ball bearing 5
If the retaining plate has been removed, use Loctite 243 for the two
countersunk bolts during assembly.
Oil ducts 6
Use compressed air to clean all oil ducts. Ensure that the oil ducts are
not clogged.
8
7
9
Roller bearing of crankshaft 7
From outside press crankshaft roller bearing inwards using a suitable
mandrel.
Press in new roller bearing from inside up to the stop.
Art.-Nr. 3.206.006 -E
Grooved ball bearing of main shaft 8
Press in new grooved ball bearing from inside up to the stop.
!
CAUTION
!
DO
NOT USE FORCE WHEN PRESSING THE GROOVED BALL BEARING AGAINST THE
RETAINING PLATE 5 TO AVOID A BENDING OF THE PLATE, WHICH WOULD RESULT IN
EXCESSIVE AXIAL PLAY OF THE MAIN SHAFT.
Needle bearing of kickstarter shaft 9
Press in new needle bearing from inside until flush.
3
Bypass valve
Test valve piston, tight fit and pressure spring for damage.
Minimum length of the pressure spring bk: 23,5 mm
Repair manual KTM LC4
10
NOTE: The opening pressure of the bypass valve is reduced when the
length of the pressure spring decreases below 23,5 mm. This reduces
the oil pressure and causes engine damage.
Ensure that neither the lubrication bore of the roller bearing A nor the
oil ducts of the oil pumps are clogged.
– After the housing half has cooled down, check bearings for tight fit.
– Finally, insert both dowels so that the dowel with internal diameter
15.4 mm is mounted at the rear (swingarm pivot).
A
5-6D
B
C
Crankshaft
If the conrod bearing is replaced, take care to properly position the
crankpin. The bores of the crank web B and crank pin C must
coincide.
!
CAUTION
!
IF
THE CRANK PIN IS PRESSED IN THE WRONG POSITION, THE CONROD BEARING IS
SUPPLIED INSUFFICIENTLY OR NOT AT ALL WITH ENGINE OIL, WHICH RESULTS IN
BEARING DAMAGE.
If the crankshaft is continued to be used, check crankshaft journals for
run out. Place crankshaft on a roller block or a similar device and check
the outer end of the journals for run out with a dial gauge.
run out of crankshaft journals: max. 0.04 mm (0.0016 in)
The radial clearance and axial clearance on the conrod bearing must be
checked.
radial clearance: max. 0.05 mm (0.0019 in)
axial clearance: max. 1.00 mm (0.04 in)
– If the crankshaft roller bearings are replaced, the inner rings on the
crankshaft should also be changed.
– Heat special tool on a heating pad up to approx. 150°C and slip it on
the inner ring immediately. Press the special tool together tightly to
obtain a good heat transfer and pull the inner ring off the crankshaft.
– To mount the new inner ring, heat the special tool again to approx.
150°C, engage the inner ring and slip it on the crankshaft journal
immediately.
– In order to safely press on new rings, a middle panel should be
inserted between the crankshaft webs. This panel should be big
enough to be supported on both sides, so that the crankshaft lies
free and accessible.
NOTE: Because LC4-E models have different diameters of inner
crankshaft bearing rings, it is necessary to have both special tools
(584.29.037.040 and 584.29.037.043).
!
CAUTION
!
NEVER CLAMP THE CRANKSHAFT WITH A CRANKSHAFT JOURNAL OR WEB IN THE
VICE, AND NEVER TRY TO KNOCK THE INNER RING FREE. THE CRANKSHAFT WEBS
MAY BE COMPRESSED THEREBY MAKING THE CRANKSHAFT UNUSEABLE.
5-7D
Measuring and adjusting of crankshaft axial clearance
– Should the crankshaft, engine housing, or a roller bearing be
replaced, the axial clearance of the crankshaft should also be
checked.
– The housing should be laid inside upwards, then measure the
distance from the sealing area to the inner rings of the roller
bearings. Note the readings and then add on 0.3 mm to allow for
gasket thickness.
– Measure the crankshaft at touching points and then subtract the
measured value from the housing dimensions. This figure will be the
axial play of the crankshaft, which should be 0.03- 0.12 mm (0.0010.005 in).
EXAMPLE:
Left-hand housing half
Right-hand housing half
Gasket
Total housing dimension
Crankshaft dimension
Axial play present
+
+
=
–
=
33.0
32.8
0.3
66.1
65.8
0.3
mm
mm
mm
mm
mm
mm
1.300
1.290
0.012
2.602
2.590
0.012
(
(
(
(
(
(
in)
in)
in)
in)
in)
in)
The compensating washers should be equally distributed between the
two sides of the crankshaft. In our example, one compensation washer
(≠ 0.1 mm / 0.004 in.) must be mounted on either side.
Art.-Nr. 3.206.006 -E
Checking the piston
– Replace the piston in the case of excessive oil consumption or
grooves in the piston skirt.
– If reinstalling the old piston perform the following steps:
1. Piston bearing surface - check for damage
2. Piston ring grooves - the piston rings must move easily in the
groove. Old piston rings or sandpaper (400 grit) may be used to
clean the piston ring grooves.
3. Piston rings - check for damage and end gap (see below).
4. The piston pin must move freely in the piston when mounted. If the
piston pin changed its color badly or shows running traces, it must
be replaced. Insert piston pin also into the conrod and check for
clearance. Maximum clearance in the conrod eye 0.08 mm (0.003
in).
Repair manual KTM LC4
NOTE: When in place, the piston pin may not have any play. It must be
possible to shift it with slight counterpressure.
5-8D
Mounting instructions for piston rings
– Insert the oil scraper ring in the lower ring groove. Side of ring
marked facing piston head.
– Mount compression ring (tapered compression piston ring) in middle
ring groove. Side of ring marked facing piston head.
– Insert the compression ring (rectangular ring) in the upper piston ring
groove (the surface marked must be on top).
ELKO
Ø 89 mm
ELKO
Ø 95 mm
ELKO
Ø 101 mm
ARIAS
Ø 101 mm
O
O
O
N 100
Tapered ring
TOP
TOP
TOP
N 101
Oil scraper ring
ELKO
TOP
TOP
–––
Compression ring
Piston ring end gap
– Insert pisto ring into the cylinder and adjust. Piston ring must be
approx. 10 mm (1/2 inch) from top of cylinder.
– The end gap B can now be checked which a feeler gauge.
Compression rings: max. 0.60 mm (0.023 in)
Oil scraper ring:
max. 0.80 mm (0.03 in)
If the end gap is greater check piston and cylinder for wear. If piston
and cylinder wear are within the permitted tolerance limits, replace the
piston ring.
Measuring piston and cylinder, determining the piston
fitting clearance
– In order to determine the wear of the cylinder, measure the cylinder
center of the running area with a micrometer.
– Measure the diameter of the x-axis and the y-axis in order to check
for oval wear, if any.
x
y
– The piston is measured on the piston skirt across to the piston pin as
shown in the illustration.
– The cylinder diameter minus the piston diameter yields the piston
assembly clearance.
Piston assembly clearence: see Technical Specification
5-9D
Cylinder – nikasil coating
Nikasil is the brand name for a cylinder coating process, developed by
the piston manufacturer Mahle. The name is derived from the two
materials used in this process - a nickel layer into which the particularly
hard silicon carbide is embedded. The main advantages of the Nikasil
coating are excellent heat dissipation and thus better power output, low
wear and low weight of the cylinder. The worn coating can be
regenerated at low cost provided that the running surface of cylinder is
flawless.
Recoated cylinder
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
If the Nikasil coating of your cylinder is worn but undamaged, you may
obtain a recoated cylinder at your KTM dealer (new Nikasil coating on
used cylinder).
It may be that your spare cylinder shows color changes on the exterior
side.
5-10D
Disassembling the cylinder head and checking the
components for wear
Three-Bond Dichtmasse
Three-Bond Gasket
– Mount cylinder head in vice using the studs. Do not allow it to rest
on sealing surface.
– Mark valves and remove using special tool (see illustration).
– Clean all parts.
Sealing area
Check spark plug threads and valve seats for damage or cracks. Check
the sealing area to the cylinder for distortions with a straightedge and a
feeler gauge. Distortion limit 0.10 mm (0.004 in).
Valve guides
The valve guides are checked with a limit plug gauge 1 (Ø 7.05 mm).
If the limit plug gauge can be easily inserted into the valve guide, the
guide must be replaced in a specialized workshop.
Valve seats
The valve seats must not be pocketed. Seat sealing width: intake max.
1.5 mm (0.059 in); exhaust max. 2.0 mm (0.079 in). Grind valves if
necessary.
1
Valves
Check valve heads for wear and run out. Max. run-out on valve heads
0.03 mm (0.001 in). Valve seats should not be pocketed. The sealing
area must be located in the center of the valve seat. The valve stem is
hard-chrome plated. Experience shows that wear appears primarily on
the valve guide.
Valve springs
Only visual check for breakage or wear is necessary.
Valve stem seals
Always renew valve stem seals when the valves are removed.
Intake flange
Check flange surface for distortion, scrape on glas plate if necessary.
5-11D
Disassembling the cylinder head top section and checking
the components for wear
– Simply pull the rocker arm axles 1 out of the cylinder head top
section. Then take both rocker arms 2 together with thrust washers
3 and bn out of the cylinder head top section.
Undo bolt 4 and remove
the following components:
15
1
15
12
3
– Press the decompression shaft bk inwards and take it out of the
cylinder head top section together with the washers bl.
– Clean all components.
1
2
Rocker arm shafts 1
The rocker arm shafts must be free of grooves and should turn easily
within the rocker arms 2.
3
14
2
12
13
Washer 5
Decompression shaft lever 6
Covering disc 7
O-ring 8
Decompression lever spring 9
14 13
10
Rocker arm rollers bm
The rocker arm rollers must move smoothly. Rocker arm rollers must be
removed in the case of radial clearance.
Adjusting screws bo
The contact surfaces of the adjusting screws must be plane.
Art.-Nr. 3.206.006 -E
Decompression shaft bk
Check for smooth operation and clearance in the bearing bore.
6
4
5
7
8
9
11
10
Pre-assembling the cylinder head top section
Repair manual KTM LC4
– Insert decompression shaft bk with compensation washers bl into the
top section.
– Mount the new O-ring 8, the decompression lever spring 9 and
the cover disc 7 in such a way that the O-ring fits into the recess of
the cover disc.
– Mount the decompression shaft lever 6.
– Apply Loctite 243 to the thread of bolt 4 and mount the bolt
together with washer 5.
– Hook the decompression lever spring onto the decompression shaft
lever.
!
CAUTION
!
THE
DECOMPRESSION SHAFT MUST EXHIBIT NO AXIAL PLAY WHEN THE ALLAN HEAD
BOLT 4 IS TIGHTENED. TO ENSURE THAT THE O-RING 8 fORMS A SEAL, IT MUST BE
SLIGHTLY PRESSED AGAINST THE TOP SECTION BY THE COVER DISC 7. HOWEVER,
THE PRESSURE ON THE O-RING MUST NOT BE EXCESSIVELY HIGH AS THE
ADJUST OUT WITH
DECOMPRESSION
SHAFT
WILL
BECOME
SLUGGISH.
COMPENSATION WASHERS bl IF NECESSARY.
13
NOTE: Discs bl are available 0.15 mm, 0.30 mm and 0.50 mm thick.
– Mount new O-rings bp on rocker arm shafts 1.
– Mount rocker arms 2, thrust washers 3 and rocker arm shafts 1.
– On the side of the water pump one thrust washer bn ≠ 1.0 mm (0.04
in) must be mounted.
– The axial play on the opposite side is roughly equalized with thrust
washers 3 ≠ 1.0 (0.04 in) and ≠ 0.5 mm (0.02 in).
The axial clearance of the rocker arm axles must be 0.20 - 0.30 mm.
5-12D
Checking the components of the timing mechanism for wear
Timing chain guide 1
Check for signs of wear.
8
Timing chain tensioner 2
Check for signs of wear.
6
5
Timing chain 3
Check rollers for smooth operation and signs of wear.
LOCTITE 243
2
3
1
Timing gear 4
Check teeth for signs of wear.
Camshaft gear 5
Check teeth for signs of wear.
Grooved ball bearing 6
Check clearance.
LOCTITE 243
Safety device 7
Check for signs of wear.
4
LOCTITE 243
Camshaft 8
Check pivot points and running surfaces for signs of wear.
LOCTITE 243
7
11
9
Disassembling the camshaft and checking the components
for wear
– Remove both the stepped ring bo and the circlip bp. Carefully
remove the decompression cam bm. Keep a watch on the spring 9.
Supporting pin bk
Check for signs of wear.
Guide pin bl
Check for signs of wear.
10
Decompression cam bm
Check the contact surfaces towards the supporting pin for signs of
wear.
Spring 9
Check length (minimum length: 7.0 mm/0.275 in).
B
Camshaft bn
Check for signs of wear at pivot point A. Minimum diameter of the
pivot point 19.97 mm.
Preassembling the camshaft
9
A
13
– Place spring 9 in the bore, compress and slide decompression cam
bm over it.
– Mount circlip bp with the sharp side towards the decompression cam.
– Position the open side B of the circlip between the open spaces of
the decompression cam.
– Slide the step ring bo with open spaces over the lock washer.
12
15
14
5-13D
Automatic tensioner
– Check ratcheting pawl 1 for smooth operation and wear.
– Check thrust bolt 2 for wear at teeth.
1
2
Preassembly of automatic tensioner
– Insert thrust bolt into tensioner housing and engage ratcheting pawl
into first notch (see illustration).
1
!
CAUTION
!
IF
THE RATCHETING PAWL IS NOT ENGAGED INTO THE FIRST NOTCH THIS WILL CAUSE
EXCESSIVE TENSION OF THE CHAIN.
2
Disassembling the oil pumps and checking the components
for wear
Art.-Nr. 3.206.006 -E
4
NOTE: The two oil pumps are similar in design but work at different
speeds. Disassemble and check the oil pumps separately to avoid mixing
up of components.
3
– Remove screw 3 and take off the oil pump cover 4.
– Pull the oil pump shaft 5 out of the oil pump housing together with
the bearing needle.
– Take the inner rotor 6 and the outer rotor 7 out of the oil pump
housing.
– Clean all components and check for signs of wear.
Repair manual KTM LC4
7
5
– When reassembling the unit insert the inner rotor and the outer rotor
into the oil pump housing, making sure that the point faces the
inside.
– Mount oil pump shaft and bearing needle
6
– Now perform the following measurements to determine the degree
of wear:
Outer rotor - oil pump housing: max. 0.20 mm
Outer rotor - inner rotor: max. 0.20 mm
– Fill the oil pump housing with oil and mount the oil pump cover.
– Apply Loctite 243 to the thread of screw 3 and mount the screw.
!
FILL
CAUTION
OIL PUMPS WITH OIL BEFORE PREASSEMBLING.
!
5-14D
Oil lines (SX, SXC)
– Check oil lines and banjo bolts for damage and clear passage.
– When repairing the engine, the microfilter 1 and the oil filter 2
must be replaced.
2
1
150
LOCTITE 243
LOCTITE 243
Oil lines (SC)
– Check oil lines and banjo bolts for damage and clear passage.
– When repairing the engine, the microfilter 3 and the oil filter 4
must be replaced.
4
3
150
LOCTITE 243
LOCTITE 243
5-15D
Oil lines (660 SMC)
– Check oil lines and banjo bolts for damage and clear passage.
– When repairing the engine, the microfilter 1 and the oil filter 2
must be replaced.
2
1
4
C
L
LOCTITE 243
LOCTITE 243
Oil lines (Models with frame oil)
Art.-Nr. 3.206.006 -E
– Check oil lines and banjo bolts for damage and clear passage.
– When repairing the engine, the fine filter 3 and the oil filter 4
must be replaced.
4
150
3
Repair manual KTM LC4
LOCTITE 243
LOCTITE 243
5-16D
Checking the kickstarter components for wear
9
Starter gear 1
Check the bearing for clearance (the starter gear must be in permanent
mesh with the outer clutch hub).
5
7
8
Intermediate starter gear 2
Check the bearing for clearance.
6
4
3
Kick starter shaft 3
Check the toothing for signs of wear.
1
Ratchet gear 4
Check the ascending surface and the toothing for signs of wear.
2
Stop bolt 5
Check for signs of wear.
Replace the seal ring 6
A
A
NOTE: Due to a parts change from 2000 onwards the seal ring is
blue-green and is to be mounted with the seal lip to the outer side.
Preassembly of kickstarter shaft
B
B
– Clamp kickstarter shaft with toothed end in vice (use soft jawcovers).
– Mount circlip 7 in lower ring groove.
– Fit spring guide 8 with collar facing downwards and circlip 9 with
sharp edge facing upwards.
– Remove kickstarter shaft from vice and fit ratchet gear spring.
– Mount the ratchet gear 4 on the kickstarter shaft in such a way that
the markings A and B coincide.
Clutch cover
Balancer shaft bearing bk
Use the bearing extractor tool with insert to remove the grooved ball
bearing from the bearing seat.
Insert the new bearing into the seat and ensure flush fit.
Seal ring bl
Use a screwdriver to lever the old shaft seal ring out of the clutch cover.
Insert the new shaft seal ring and ensure flush fit.
10
11
14
13
Replacing absorbing elements of the outer clutch hub
– Drill open the clutch rivets bm in area of the retaining bracket bn and
take off the parts.
NOTE: When performing repair work always exchange all 8 absorbing
elements.
!
CAUTION
!
DAMPING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN bo. TO
ENSURE THAT THE OUTER CLUTCH HUB AND RETAINING BRACKET ARE POSITIONED
DIRECTLY ON THE PRIMARY GEAR CROWN, THE PARTS MUST BE HELD IN POSITION
UNDER TENSION WITH THE CLUTCH RIVETTING TOOL C BEFORE RIVETTING.
THE
12
– Apply the special tool as shown, screw together and lock the rivets
with a pointed mandrel and a round mandrel.
C
Locking pressure for the pointed mandrel: approx. 4000 kg
Locking pressure for the round mandrel: approx. 5000 kg
5-17D
7
9
13
11
12
10
8
1
14
Art.-Nr. 3.206.006 -E
LOCTITE 243
3
4
From model 2003 on
5
2
6
Checking the clutch components for wear
Thrust bearing 1 – Check for signs of wear.
Push rod 2 – Check the face side for signs of wear.
Repair manual KTM LC4
Clutch release shaft 3, sealing cup 4 and needle bearing 5 – Check for damage and signs of wear.
Clutch pressure springs 6 – Minimum length: 34.5 mm (1.36 in) (length/new spring: 37 mm (1.457 in)).
Replace all 6 springs if necessary.
Clutch discs 7 – Clutch discs must be plane.
7 steel discs ≠ 1.5 mm (0.066 in) must be free of grooves.
8 lining discs ≠ 2.7 mm (0.106 in), wear limit: 2.5 mm (0.1 in)
Inner clutch hub 8 – Check both the exterior and the interior toothing for signs of wear.
Needle bearing 9 – Check for signs of wear.
Outer clutch hub bk – Check if all rivets bm are tight.
Absorbing elements bl
Power transmission from the primary drive to the clutch is cushioned by rubber elements bl. These rubber elements must be
checked in the course of normal checking for signs of wear. It is recommended to check the elements while disassembling the
engine. Try to turn the outer clutch hub after removing the inner clutch hub (engine will lock). Dead travel should be impossible.
Check O-ring bo for brittleness and cracks. If the cross section of the O-ring is oval (deformed) replace the O-ring.
5-18D
Checking the shift mechanism components for
wear
B
Shift forks 1
Check the fork leaf for signs of wear.
Check the shift roller driving pin 2 for signs of wear.
7
8
5
9
10
11
Shift rolls 3
Check the shift rolls for hairline cracks and pressure marks.
Additionally, make sure that the shift rolls turn easily on the
driving pins 2 of the shift forks.
Shift roller 4
Check the shift grooves for signs of wear.
Check the two grooved ball bearings of the shift roller for
wear.
Slide plate 5
Check the contact surfaces for signs of wear.
Check the return surface of the slide plate for signs of wear
(replace in the case of deep grooves).
1
2
4
1
3
3
1
Slide guides
Check clearance (maximum clearance between guide bolt
and slider 0.70 mm / 0.027 in.).
Guide bolt 7
Check for tight fit and signs of wear.
3
Preassembly of shift shaft
– Push steel disc 8 (14x28x2 mm) onto shift shaft.
– Mount the return spring 9, positioning the offset A on the side of
the shift quadrant.
A
– Mount spring sleeve bk with shallower collar facing shift quadrant.
– Cross return spring legs and hook in shift quadrant.
– Grease and mount both O-rings bl.
5-19D
Shift mechanism support
2
– If the grooved ball bearing 1 of the shift roller must be exchanged,
press the new grooved ball bearing all the way into the seat.
1
!
CAUTION
!
TO
PREVENT DAMAGING OF THE SHIFT MECHANISM SUPPORT, DO NOT APPLY
EXCESSIVE FORCE WHEN INSERTING THE GROOVED BALL BEARINGS.
– Apply Loctite 243 to the screw and fix the bearing.
– The new needle bearing of the kickstarter shaft 2 has to be pressed
in flush.
Balancer shaft
Check bearing seat A for wear and tear.
3
A
Check three allan head bolts 3 for tight fit.
Disassembling and reassembling the water pump
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
5
10
9
Remove the water pump cover 4 together with the gasket.
– Remove circlip 5 from the water pump shaft 6 and pull shaft and
water pump wheel 7 out of the grooved ball bearings.
6
8
11
7
4
– If grooved ball bearings 8 are replaced, remove circlip 9 and shaft
seal ring bk and press out bearing.
– Properly lubricate new grooved ball bearings and press in to stop
with the open sides facing each to them.
– Mount circlip 9.
– Cover new shaft seal ring with Loctite 648 and press in with the
printing facing outward.
– Lubricate water pump shaft and mount carefully so as to not
damage sealing lips of shaft seal ring and check for smooth working.
– Mount circlip 5 and water pump cover 4 with gasket.
– Finally, remove silicone from the sealing flange and mount 2 new
O-rings bl.
5-20D
Important note regards working on transmission
– Fix the main shaft or countershaft, respectively, in the vise (use
special vise jaws to avoid damaging of the shafts) and remove the
gear wheels.
– Clean and check all parts.
11
Always use new lock washers when performing repair work on the
transmission !
10
Check the tooth profiles of transmission shafts and sliding gears for
signs of wear.
Slide the sliding gears onto the transmission shafts and check the
toothing for easy operation.
9
Check the pivot points of the transmission shafts.
Mount the idler gears with the bearings on the transmission shafts and
check for clearance.
Check the needle bearings of the idler gears.
8
7
Assembling the main shaft
6
5
NOTE: Check all gears for smooth operation.
4
3
2
1
– Mount the main shaft in a vise with the gearwheel facing
downwards (use protective jaws).
– Mount the needle cage 1 and slide the 3rd gear 2 with the shift
dogs facing upwards.
– Mount stop disc 3 (22.7x32x1.5 mm) and the circlip 4 with the
sharp edge facing up.
– Mount 4th gear 5 with the shift groove facing down.
– Secure it with the circlip 6 with the sharp edge down and mount
the stop disc 7 (22.7x32x1.5 mm).
– Mount needle cage 8 and 5th gear 9 with the shift dogs down.
– Mount 2nd gear bk and stop disc bl (20.2x35x1 mm).
5-21D
Important note regards working on transmission
16
– Fix the main shaft or countershaft, respectively, in the vise (use
special vise jaws to avoid damaging of the shafts) and remove the
gear wheels.
– Clean and check all parts.
15
Always use new lock washers when performing repair work on the
transmission !
Check the tooth profiles of transmission shafts and sliding gears for
signs of wear.
14
Slide the sliding gears onto the transmission shafts and check the
toothing for easy operation.
Check the pivot points of the transmission shafts.
13
Mount the idler gears with the bearings on the transmission shafts and
check for clearance.
12
Check the needle bearings of the idler gears.
11
Assembling the counter shaft
Art.-Nr. 3.206.006 -E
10
–
–
–
–
9
–
–
–
–
8
–
Mount counter shaft in vise with collar facing downwards.
Oil and mount needle cage 1.
Slide 2nd gear 2 over needle cage with collar facing downwards.
Mount stop disc 3 (22.7x32.0x1.50 mm) with clearance towards
gear wheel and circlip 4 with sharp edge facing upwards.
Mount 5th gear 5 with shift groove facing upwards.
Fit circlip 6 with sharp edge down and stop disc 7 (22.7x32.0x1.50
mm).
Mount needle cage 8 and fit 4th gear 9 with shift dogs facing up.
Mount stop disc bk (22.7x32.0x1.50 mm) and circlip bl with sharp
edge facing up.
Fit 3rd gear bm with shift groove down and mount stop disc
(22.2x35.0x1.50 mm) bn.
Mount needle cage bo, 1st gear bp with collar facing up and fit stop
disc (20.2x35.0x1.0 mm) bq.
7
–
6
NOTE: A roller bearing was installed in the 660 SMC model, thus a stop
disc is unnecessary.
Check all gears for smooth operation.
Repair manual KTM LC4
5
4
3
2
1
5-22D
Removing the intermediate gear
–
–
–
–
Remove the starter cover.
Pull out the bearing bolt 1.
Remove the intermediate gear and the needle bearing.
Check the parts for signs of wear.
– Insert the intermediate gear with the collar downward into the
housing for preassembly.
– Oil the needle bearing and install it with the bearing bolt.
– Do not yet replace the starter cover.
1
Checking the freewheel
2
3
– Insert the freewheel gear 2 into the freewheel.
– The freewheel gear must turn clockwise.
– The freewheel gear must lock without empty run if turned
anticlockwise.
– Check the reduction gear 3 and the needle bearings for signs of
wear.
– Check the needle bearing of the freewheel gear for signs of wear.
Replacing the freewheel hub
– Squeeze the spreader ring 4 with the circlip pliers and remove it
together with the freewheel.
– Check the freewheel segments for signs of wear.
– Check the freewheel hub sections at the freewheel running surface
for signs of wear.
– Heat the flywheel to a temperature of approx. 80° C (176° F) and
remove the 6 bolts.
4
!
!
CAUTION
MAKE
SURE THAT THE FLYWHEEL IS NOT HEATED BEYOND
AVOID LOOSENING OF THE MAGNETS.
80° C (176° F)
TO
– Carefully tap the side of the freewheel hub with a plastic hammer
and take off the freewheel hub.
A
– Apply Loctite 648 to the flange surface A of the flywheel and the
freewheel hub.
– Mount the freewheel hub on the flywheel.
– Apply Loctite 648 to the thread of the bolts and tighten them
crosswise (18 Nm).
!
ALWAYS
USE NEW BOLTS
(12.9)
CAUTION
AND APPLY LOCTITE 648
!
TO THE THREADS.
– Thoroughly oil the free-wheel and insert it into the freewheel hub.
– Insert the spreader ring into the groove with a pair of circlip pliers
and make sure that it properly rests in the groove.
Electric starter motor
5
– The starter showed only slight signs of wear after 10.000 starting
processes, and exchanging individual parts must be considered
uneconomical. Therefore, such work is not described in the present
documentation.
– Exchange the O-ring 5 at the starter flange (incl. in the gasket set).
5-23D
Ignition (Kokusan 4K2)
General information
The measurements described below will only reveal severe
problems. Coil short circuits leading to weak ignition sparks
or low generator output, respectively, can only be detected
with the help of an ignition test bench. In the case of
malfunction always check the cables and the plug and socket
connections of the ignition system first.
Make sure to select the correct measuring range when
performing measurements.
LOCTITE 648
LOCTITE 243
LOCTITE 243
LOCTITE 648
SILICON
Checking the stator and the pulse generator (Kokusan 4K2)
Art.-Nr. 3.206.006 -E
Use an ohmmeter to perform the following measurements:
NOTE: The measuring must be performed at a temperature of 20° C.
Otherwise significant deviations must be expected.
MEASUREMENT
Stator
Pulse generator
CABLE COLORS
red/black – black/red
yellow – black/red
yellow – red/black
white – green
RESISTANCE
0.45 – 0.56 Ω
80 – 120 Ω
Replace the stator and/or the pulse generator if the measured values
deviate significantly from the setpoint values or in the case of continuity
between one of the cables and ground.
Replacing the stator (Kokusan 4K2)
Repair manual KTM LC4
– Loosen the 3 bolts and remove the stator.
– Insert a new stator into the ignition cover.
– Apply Loctite 243 to 3 new bolts and tighten the bolts.
– Insert the cable guide in the opening provided for that purpose in
the ignition cover.
5-24D
Ignition (SEM)
General information
The measurements described below will only reveal severe
problems. Coil short circuits leading to weak ignition sparks
or low generator output, respectively, can only be detected
with the help of an ignition test bench. In the case of
malfunction always check the cables and the plug and socket
connections of the ignition system first.
Make sure to select the correct measuring range when
performing measurements.
+ POLE
– POLE
MEASURE VALUE
black
red
1.7 kΩ
red
black
1.7 kΩ
black
green
165 Ω +/- 20 Ω
green
red
1.7 kΩ
yellow
yellow
1.0 Ω
Checking the stator (SEM)
Perform the measurements indicated to the left with an ohmmeter.
NOTE: The measuring must be performed at a temperature of 20° C.
Otherwise significant deviations must be expected.
The stator must be exchanged if any of the measured values deviates
significantly from the respective nominal value or in the case of
continuity between one of the cables and ground.
Replacing the stator (SEM)
– Remove bolt 1 with retaining bracket.
– Remove the three clamp bolts 2 and lift the stator out of the
ignition cover.
2
1
– Mount the new stator in such a way that the timing mark A is
visible in the checking hole on the rear side.
– Apply Loctite 243 to the threads of the bolts 2 and insert the bolts
without, however, tightening them yet.
– Apply Loctite 243 to the thread of bolt 1, turn the stator clockwise
all the way to the stop.
– Fix the cable strand with retaining clips and insert the rubber cable
guide into the opening provided for that purpose.
– Turn the stator until the mark becomes visible in the peephole. Then
tighten the bolts 2.
A
5-25D
Ignition (Kokusan 4K-3)
General information
The measurements described below will only reveal severe
problems. Coil short circuits leading to weak ignition sparks
or low generator output, respectively, can only be detected
with the help of an ignition test bench. In the case of
malfunction always check the cables and the plug and socket
connections of the ignition system first.
Make sure to select the correct measuring range when
performing measurements.
LOCTITE 243
LOCTITE 243
LOCTITE 243
Checking the stator (Kokusan 4K-3)
Use an ohmmeter to perform the following measurements.
Note: The measuring must be performed at a temperature of
20° C. Otherwise significant deviations must be expected.
Art.-Nr. 3.206.006 -E
Replace the stator if the measured values deviate significantly
from the setpoint values.
Ignition
4K-3
2
Measure
Cable colours
Resistance
Pulser coil
red – green
100 Ω 20%
Stator
black/red – red/white
12,7 Ω 20%
Charging coil
ground – yellow
0,65 Ω 20%
white – yellow
0,16 Ω 20%
Installing a new stator (Kokusan 4K-3)
1
3
1
4
Repair manual KTM LC4
3
4
– Remove the 2 bolts 1 and take the cover plate 2 out of the ignition
cover.
– Remove the 2 bolts 3 of the pulse generator and the 2 bolts 4 of
the stator.
– Undo bolt 5 and take the retaining platelet out of the ignition
cover. Take the stator and the pulse generator out of the ignition
cover.
NOTE: When reassembling the unit, degrease and apply Loctite 243 to
the threads of all bolts.
– Put the new stator into the ignition cover and fix it with the two
bolts 4.
– Position the pulse generator in the ignition cover and fix it with the
two bolts 3.
– Put the cable guide into the recess provided for this purpose and fix
the cover plate 2 with the two bolts 1.
– Position the wiring harness, taking care to avoid tension, and use the
retaining platelet and the bolt 5 to fix it in the ignition cover.
5
6-1D
ASSEMBLING THE ENGINE
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
INDEX
MOUNTING THE KICKSTARTER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
MOUNTING TRANSMISSION AND SHIFT MECHANISM . . . . . . . . . . . . . .6-2
ADJUSTMENT OF RETURN SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
PRETENSIONING OF THE STARTER SPRING . . . . . . . . . . . . . . . . . . . . . . .6-4
MOUNTING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
ASSEMBLY OF ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
MOUNTING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
MOUNTING THE ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
MOUNTING THE TIMING GEAR AND THE TIMING CHAIN . . . . . . . . . . . .6-7
MOUNTING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
MOUNTING THE BALANCER SHAFT AND THE PRIMARY PINION . . . . . . .6-8
MOUNTING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
MOUNTING THE CLUTCH DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
INSTALLING THE CLUTCH RELEASE SHAFT . . . . . . . . . . . . . . . . . . . . . . . .6-9
ADJUSTING THE CLUTCH RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
MEASURE DIMENSION „Y“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
MOUNTING PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
MOUNTING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
MOUNTING THE CAMSHAFT, TIMING MARKS . . . . . . . . . . . . . . . . . . . .6-12
MOUNTING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
MOUNTING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . . . . . .6-14
MOUNTING THE AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . . .6-14
AUTOMATIC DECOMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . .6-14
ADJUSTMENT OF VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
MOUNTING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
MOUNTING THE ELECTRIC STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . .6-16
MOUNTING THE IGNITION (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . . .6-16
ADJUSTING THE PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
MOUNTING THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
ADJUSTMENT OF IGNITION POINT (SEM) . . . . . . . . . . . . . . . . . . . . . . .6-18
MOUNTING THE EPC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . .6-18
MOUNTING THE IGNITION (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . .6-19
ADJUSTMENT OF IGNITION POINT (KOKUSAN 4K-3) . . . . . . . . . . . . . .6-19
MOUNTING THE OIL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
MOUNTING THE CLUTCH RELEASE LEVER . . . . . . . . . . . . . . . . . . . . . . .6-20
MOUNTING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . .6-20
MOUNTING THE WATER HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
POURING IN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
MOUNTING THE KICKSTARTER AND THE SHIFT LEVER . . . . . . . . . . . . .6-21
6
6-2D
– Place left-hand housing half in engine work stand.
1
Mounting the kickstarter unit
– Insert stop disc (22.2x35x2 mm), starter gear 1, needle bearing and
stop disc 2 (22.2x30x1.5 mm) into housing.
2
– Insert the pre-assembled kickstarter shaft into the bearing seat,
putting it through the starter gear. Make sure that the starter spring
slips into opening A of the housing.
A
Mounting transmission and shift mechanism
– Insert stop disc (20.2x35x1 mm), 1st gear wheel 3 with collar facing
down into the housing and the needle bearing into the idler gear.
Art.-Nr. 3.206.006 -E
3
NOTE: A roller bearing was installed in the 660 SMC model, thus a stop
disc is unnecessary.
Repair manual KTM LC4
– Mount transmission shafts together and slightly turn them.
– Grease the driving pins of the shift forks and mount the shift rollers 4.
– Hook shift fork with legs of same length in the sliding gear of the
main shaft.
– Fit the other two shift forks into the gears of the counter shaft,
paying attention to the marks applied during disassembly.
!
USED
4
CAUTION
!
SHIFT FORKS SHOULD BE MOUNTED IN THE SAME SLIDING GEAR AS BEFORE.
6-3D
2
1
3
– Insert shift roller 1 into the housing with the holder for the locking
piece facing up.
– Hook the shift forks into the shift roller and mount shift rails 2 + 3.
The shorter shift rail 3 must be fitted to the main shaft.
– Before mounting the shift mechanism support, check whether the
two dowels have been fitted.
– Mount shift mechanism support, secure the two bolts 4 with Loctite
243 and tighten.
4
4
– Put the washer (6.2x18x2 mm), the locking lever, the locking spring
bushing and the locking lever spring onto the third bolt.
– Apply Loctite 243 to the thread of the bolt and mount it.
6
– Pull locking lever 5 away from the shift roller.
– Put the shift drum locating device 6 onto the shift roller, apply
Loctite 243 to the thread of the bolt and fix the shift drum locating
device.
5
– Oil the O-rings and grease the shank of the shift shaft.
– Slide preassembled shift shaft into kickstarter shaft.
– At the same time, push back the slide plate 7 and make sure that
the ends of the return spring 9 are resting against the centering cup
of the shift mechanism support 8.
9
8
7
6-4D
Adjustment of return spring
– Engage second or third gear.
– Check free travel of slide plate and check shift pin play.
– The free travel of the slide plate is the path this component travels
until the shift roller is moved. The return spring pressure will be felt.
Proceeding from the basic position, this free travel A should be
identical for upward and downward movement.
– If necessary, the free travel must be readjusted by adjusting the
return spring.
– For this purpose, remove the shift shaft and bend the return spring
by an appropriate amount at points B using a pair of pliers. Refit
shift shaft. After the shifting shaft has been fitted, the return spring
must rest against shift pin 1 and against the centering cup on the
shift mechanism support.
– If necessary, bend the return spring accordingly.
1
B
Pretensioning of the starter spring
Art.-Nr. 3.206.006 -E
– Fit kickstarter onto kickstarter shaft, turn one revolution in starting
direction and hold in this position.
– Mount the stop bolt 2 together with a new seal ring and tighten it
manually.
!
CAUTION
!
IT
MUST BE POSSIBLE TO MOUNT THE STOP BOLT WITHOUT APPLYING EXCESSIVE
FORCE. IF IT IS NOT POSSIBLE TO MOUNT THE STOP BOLT MANUALLY, TURN THE
KICKSTARTER SHAFT FURTHER AGAINST THE FORCE OF THE SPRING UNTIL THE STOP
BOLT CAN BE MOUNTED.
– Move kickstarter to stop and remove.
– Tighten stop bolt 2 with 50 Nm.
2
– Place O-ring 3 (22x1 mm) and inner ring 4 of roller bearing on the
counter shaft with the collar facing the gear.
– Mount stop disc 5 (20.2x35x1 mm) onto the main shaft.
Repair manual KTM LC4
4
3
5
Mounting crankshaft
– Grease the shaft seal ring of the crankshaft and thoroughly oil the
roller bearing of the crankshaft.
– Fit mounting sleeve onto crankshaft and place crankshaft into
bearing.
6-5D
Assembly of engine housing
– Make sure both dowels are in place in the left housing half, and put
gasket on the sealing surface. Use a little bit of grease to hold the
gasket in place.
– Grease all shaft seal rings in the left side of the housing.
– Oil all bearings in the right side of the housing and put on the
housing half. If necessary, tap lightly with a plastic mallet and turn
transmission shafts.
– Check to make sure that the gasket is in the proper position before
final assembly.
– Grease housing bolts (threads and contact surfaces of bolts heads).
Insert bolts and assemble the housing (see sketch for bolt lengths).
– Check all the shafts for smooth operation before and after tightening
with 7-8 Nm.
– Mount case in mounting rack and check function of gear-change by
engaging all gears.
– Check crankshaft axial clearance (0.03 - 0.12 mm) (0.0012 - 0.0047
in) and fit crankshaft locking bolt.
SX, SXC
M6x30
M6x55
SC
M6x65
M6x30
M6X55
NOTE: On Adventure-models bolts M6x35 are used instead of the two
upper bolts M6x30.
LC4-E
M6x65
M6x30/35
M6x30
M6x55
M6x95
640 LC4 2003 on
M6x65
M6x30/35
M6x55
M6x55
M6x30
NOTE: On Adventure-models bolts M6x35 are used instead of the two
upper bolts M6x30.
6-6D
SXC/SMC 2003 on
M6x65
M6x55
M6x30
Mounting oil filter
– Fit oil filter with rubber gasket onto the connection in the oil filter
cover.
– Fit a new O-ring into the oil filter cover groove or use new gasket
and fix the oil filter cover with the 3 bolts, tighten bolts with 5 Nm.
Mounting the engine sprocket
Art.-Nr. 3.206.006 -E
3
– Lubricate O-ring (25x2 mm) with oil and slide over countershaft.
– Slide distance bushing 1 in position so that O-ring is in correct
position.
NOTE: The distance bushing for Duke and Supermoto-models is 2mm
thicker.
2
!
DO
CAUTION
!
NOT REVERSE DUST LIP OF THE SHAFT SEAL.
– Fit the engine sprocket with the collar facing the housing.
1
NOTE: For Duke and Supermoto-models an additional 2 mm washer is
used.
4
– Apply Loctite 243 to thread of sprocket bolt.
– Mount spring retainer 2 and sprocket bolt 3.
– Apply counterpressure with the sprocket holding spanner and tighten
sprocket bolt.
Repair manual KTM LC4
NOTE: Tighten bolts with quality 8.8 to 40 Nm, bolts with quality 10.9
to 60 Nm.
5
NOTE (from model 2003 on):
A collar nut 4 and a lock washer 5 are installed in some of the models
instead of a collar screw.
Tightening torque off the collar nut: 60 Nm
6-7D
Mount the timing gear and the timing chain
– Insert woodruff key for timing gear into crankshaft and fit timing
gear onto crankshaft with high collar towards housing.
– Fit timing chain onto timing gear and draw up through chain tunnel.
3
1
4
– Insert the timing chain guide 1, apply Loctite 243 to the Allen head
bolt 2 and mount.
– Apply Loctite 243 to the thread of the flat-head screw 4.
– Fasten timing chain tensioner 3 with flat head screw.
– Check timing chain tensioner for smooth operation.
2
– Insert the safety device 5, apply Loctite 243 to the Allen head bolt
6 and mount.
6
5
Mounting the oil pumps
7
8
– Clean the sealing surfaces and install the oil pumps in the engine
housing (A M6x25!)
– Degrease the threads and use Loctite 243 to secure the bolts in their
position.
– Degrease the threads of both bolts 7, apply Loctite 243 and mount
the retaining bracket 8.
A
– Put the stop discs (8.1x15x0.5 mm) onto the oil pump shafts.
– Insert the bearing needles into the oil pump shafts and slide on the
oil pump gears (high collars must face the casing; the small oil pump
gear must face the upper oil pump).
NOTE: From model 2002 onwards both oil pumps are fitted with the
same size of oil pump gear.
– Put on the upper stop discs 9 (8.1x15x0.5 mm) and mount the
locking discs bk.
10
9
6-8D
Mounting the balancer shaft and the primary pinion
– Fit balancer shaft in the bearing.
– Mount woodruff key in crankshaft and place primary pinion on the
crankshaft. When doing so, adjust the teeth of the primary pinion
and the balancer shaft in such a way that the markings A and B
coincide.
– Apply Loctite 243 to the crankshaft thread.
– Mount spring ring and hexagon nut and tighten hexagon nut to 170
Nm.
B
A
!
CAUTION
!
IF
THE BALANCER SHAFT IS NOT INSTALLED ALSO REMOVE BOTH GROOVED BALL
BEARINGS (IN THE CLUTCH COVER AND IN THE ENGINE HOUSING). OTHERWISE THE
GROOVED BALL BEARINGS WOULD DROP OUT OF THE BEARING SEATS AND CAUSE
ENGINE DAMAGE AS SOON AS THE ENGINE HEATS UP.
Mounting the clutch
1
– Fit kickstarter intermediate gear 1 onto counter shaft with clearance
space towards housing.
– Slide the inner ring and the needle bearing 2 onto the main shaft.
2
Art.-Nr. 3.206.006 -E
– Fit outer clutch hub and outer stop disc 3 (22.2x35x3 mm).
3
Repair manual KTM LC4
– Degrease the thread of the main shaft.
– Place inner clutch hub and a new safety plate on the main shaft.
– Coat the thread of the main shaft with Loctite 243 and mount
hexagon nut.
– Fit clutch holder and tighten hexagon nut to 100 Nm (60 ft.lb.).
– Remove clutch holder.
– Check clutch hub and main shaft for smooth operation and axial
clearance.
– Secure outer clutch hub hexagon nut by bending the safety plate up
into place.
6-9D
Mounting the clutch discs
– Thoroughly oil the O-ring 1 and put it onto the inner clutch hub.
– Oil the lining disc 2 (internal diameter: 127 mm) and mount it,
making sure that the disc encircles the O-ring (see illustration).
1
2
– Thoroughly oil all clutch discs before mounting.
– Alternately mount 1 steel disc and one lining disc.
NOTE: The last disc must be a lining disc.
!
MOUNT
CAUTION
!
ALL STEEL DISKS WITH THE SHARP EDGE FACING DOWNWARD.
B
– Grease the end of the push rod with Molykote grease and fit the
pressure cap together with the push rod.
– When mounting the pressure cap make sure that bore A in the
pressure cap and the pin B of the inner clutch hub coincide.
A
– Place the springs in the pressure cap and fit the HH srews with spring
retainers.
– Secure carefully to 6 Nm in a diagonal pattern, to avoid any damage
to the inner clutch hub thread.
NOTE:
– Use offset instead of flat spring retainers for 640 ccm engines.
– From model 2000 onwards spring retainers 6,5x20x2 replaced spring
retainers 6,2x20x3,2, these can be used for all models with 540, 620
and 640 engines.
Installing the clutch release shaft
– Oil needle bushings in engine housing.
– Insert the grooved ring 3 into the housing with the open side up.
– Check for the right position of the circlip 4 on the clutch release
shaft.
– Slide the release shaft into the housing until it lies on the clutch push
rod.
4
3
6-10D
– Turn the release shaft clockwise until it glides a bit further into the
housing. The push rod now sits on the release shaft.
– Apply Loctite 243 to the bolt (s).
– Fasten the retaining bracket for the clutch release 1 with bolt(s).
1
Adjusting the clutch release
– Turn the clutch release shaft clockwise to stop.
– The slot on the front side of the release shaft should now be parallel
to the sealing surface of the housing (see ill.).
PA R A L L E L
– To adjust the clutch release remove pin 2 and turn the push rod 3
with a screwdriver until the desired setting is achieved.
– Once you have completed the adjustment, the push rod is to be
secured with a pin.
Art.-Nr. 3.206.006 -E
3
!
CAUTION
!
TO
MAKE SURE THAT THE CLUTCH DISENGAGES PERFECTLY, THE CLUTCH RELEASE
MUST BE PROPERLY ADJUSTED.
2
Repair manual KTM LC4
Sealing surface of the clutch
slave cylinder
push
rod
DIMENSION „Y“
Measure the dimension „Y" (from model 2003 on)
NOTE: The dimension „Y" must be adjusted to make sure the clutch
release operates correctly.
The dimension „Y" is the distance between the sealing area of the
clutch slave cylinder and the pushrod.
– Oil the pushrod and insert in the main shaft all the way in to the
stop.
– Measure the distance between the mounting face (without the
gasket) of the clutch slave cylinder to the pushrod using a depth
gauge.
– To adjust, remove the splint 2 and turn the pushrod 3 with a
screwdriver.
– After making the adjustment, lock the pushrod with the splint again.
Dimension „Y" = 2.75 mm
Mounting piston and cylinder
– Lubricate the piston pin eye in the connecting rod and the piston pin
with oil.
– Mount piston and secure piston pin with 2 new wire circlips.
!
CAUTION
!
THE ARROW ON THE PISTON HEAD MUST POINT IN THE DIRECTION OF TRAVEL.
MOUNT WIRE CIRCLIPS IN „6 O’CLOCK” OR „12 O’CLOCK” POSITION (SEE ILL.).
12 o’clock-pos.
6 o’clock-pos.
6-11D
– Cut off the section of the housing gasket protruding around the
cylinder flange and mount 2 dowels.
– Apply sealing compound to the sections near the chain tunnel and
mount the cylinder base gasket.
NOTE:
– To facilitate the installation of the cylinder it is recommended to
place a rubber band (see illustration) around the timing chain guide
and the timing chain tensioner.
– Oil the piston, adjust the piston rings (piston rings must be turned
120 ° against each other) and mount the piston mounting ring.
– Only for 640 LC4 engines a black cylinder base gasket (0,7 mm
thickness) is used, the other LC4 engines need the green gasket
(0,5mm thickness).
– Slide the cylinder over the piston and remove the mounting ring.
!
!
CAUTION
APPLY
PARTICULAR CARE WHEN MOUNTING THE CYLINDER!
IS EXTREMELY FRAGILE.
THE
OIL SCRAPER RING
– Hook in the preassembled microfilter with the holding device onto
the rear studs and mount the collar nuts 1 at the cylinder base.
– Tighten collar nuts with 40 Nm (30 ft.lb.) crosswise.
– Then mount the bracket 2 and attach the microfilter.
NOTE: The upper edge of the piston is higher than the upper edge of
the cylinder when the cylinder is screwed down.
1
2
Mounting the cylinder head
– Check both dowels within the cylinder for proper fit.
– Mount cylinder head gasket and fit cylinder head.
– Oil the 4 bolt (threads and contact surfaces of bolt head) and then
mount with new copper seal rings.
– Tighten collar bolts crosswise in three rounds up to the prescribed
torque of 50 Nm. During the first round only tighten until a slight
resistance is felt.
5
– Mount M8 collar nuts 3 on the front and rear side of cylinder and
tighten.
– Mount and tighten bolts 4.
– Put a new seal ring on the chain guide bolt 5 and degrease the
thread.
– Apply Loctite 243 to the thread of the chain guide bolt, mount and
tighten it (30 Nm).
!
BEFORE
4
3
CAUTION
!
MOUNTING THE CHAIN GUIDE BOLT MAKE SURE THAT THE OPENING OF THE
TIMING CHAIN GUIDE IS VISIBLE THROUGH THE THREADED HOLE. IF THIS IS THE CASE
THE CHAIN GUIDE BOLT CAN EASILY BE MOUNTED WITHOUT EXERTING EXCESSIVE
FORCE.
6-12D
Mounting the camshaft, timing marks
1
B
A
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
C
A
B
C
tensioned
– Fit the camshaft gear into the timing chain so that mark A (a point)
is aligned with the top surface of the cylinder head when the timing
chain strand tensioned.
– Tilt engine to one side and place circlip 1 on camshaft gear.
– Slide grooved ball bearing flush onto the preassembled camshaft and
fit the camshaft into the camshaft gear so that the mark B and mark
C are aligned.
6-13D
– Lubricate the needle bushing 1 with oil and slide it onto the
camshaft.
– Mount camshaft together with bearing and circlip 2 into cylinder
head.
1
2
– Degrease the threads in the camshaft and the driving bolt and apply
Loctite 243.
– Mount the driving bolt together with the lock washer and the
washer (10x28x3 mm) and tighten (35 Nm/25 ft.lb).
Mounting the water pump
3
– Loosen crankshaft locking bolt and turn crankshaft until groove 3 is
at a position vertical to the sealing surface for the cylinder head top
section.
– Coat O-ring of water pump with sealing compound (Three-Bond)
and carefully mount the water pump. The flat part of the water
pump shaft must be introduced into the groove of the HH bolt.
THE
!
MARKING 4
CAUTION
!
LOCATED ON THE HOUSING OF THE WATER PUMP MUST BE FLUSH
TO THE SEAL SURFACE.
4
6-14D
2
2
Mounting the cylinder head top section
– Clean the sealing area of the cylinder head top section and apply a
thin layer of sealing compound.
– Fit dowel in the area of the spark plug.
– Carefully position cylinder head top section (do not jam with water
pump) and mount bolts.
!
COPPER
3
1
1
CAUTION
5 ALLEN
SEAL RINGS MUST BE FITTED TO THE
HEAD BOLTS
!
1, 2
AND
3.
– Tighten bolts 1 and 2 to 8 Nm diagonally.
– Tighten bolts 2 to 15 Nm.
– Tighten all other bolts of the cylinder head top section with 8 Nm.
Mounting the automatic tensioner
– Fit preassembled automatic tensioner with gasket into the cylinder.
– Mount the clamp 4 and two bolts with copper seal rings.
!
CAUTION
!
IF
THE RATCHETING PAWL IS NOT ENGAGED INTO THE FIRST NOTCH THIS WILL CAUSE
EXCESSIVE TENSION OF THE CHAIN.
– Fit pressure spring and plug 5 with gasket and tighten with 20 Nm.
Art.-Nr. 3.206.006 -E
4
5
Automatic decompression testing
– Rotate the crankshaft in the usual direction of rotation (i.e. forward).
After every other rotation, the decompression cam must be clearly
heard to click as it disengages.
Repair manual KTM LC4
NOTE: If turning of the engine does not produce a click of the
decompression cam, first of all check the tightening torque of the
driving bolt (camshaft gear).
6-15D
Adjustment of valve clearance
– Adjust piston to ignition top dead center (check marks of flywheel)
and screw crankshaft locking bolt back in.
!
!
CAUTION
IF
THE PISTON IS NOT IN IGNITION TDC, VALVES ARE OPENED AND A CORRECT
ADJUSTMENT IS NOT POSSIBLE - IN THAT CASE CRANKSHAFT MUST BE MOVED A FULL
TURN.
– Valve clearance A is measured at cold engine between valve stem
and adjusting screw.
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
CLEARANCE
CLEARANCE
CLEARANCE
CLEARANCE
CLEARANCE
CLEARANCE
400
540
620
625
640
660
:
:
:
:
:
:
INTAKE
INTAKE
INTAKE
INTAKE
INTAKE
INTAKE
0.20
0.15
0.15
0.15
0.15
0.15
mm
mm
mm
mm
mm
mm
/
/
/
/
/
/
EXHAUST
EXHAUST
EXHAUST
EXHAUST
EXHAUST
EXHAUST
0.20
0.15
0.15
0.15
0.15
0.15
mm
mm
mm
mm
mm
mm
– Tighten counternuts with 20 Nm.
– Remove the crankshaft locking bolt.
A
– Mount both valve covers with new gaskets and bolts with copper
seal rings.
– Tighten bolts with 8 Nm.
– Insert and tighten spark plug with 20 Nm.
Mounting the clutch cover
– Pour approx. 30 ml of oil into the crankshaft journal hole.
1
2
2
– Make sure that the two dowels are mounted.
– Fit new gasket and fix with dabs of grease.
– Apply grease to the shaft seal ring in the clutch cover and mount
clutch cover.
– Fit bolts and bump rubber 1 for kickstarter.
NOTE: Bolts 2 must each be provided with a copper seal ring.
– Tighten bolts with 8 Nm.
6-16D
Mounting the electric starter drive
–
–
–
–
1
Insert the woodruff key into the crankshaft.
Slide 2 needle bearings 1 onto the bearing pin of the reduction gear.
Slide the needle bearing 2 onto the crankshaft.
Oil the needle bearings.
2
– Mount the freewheel gear 3 and the reduction gear 4.
4
3
Mounting the ignition (Kokusan 4K-2)
Art.-Nr. 3.206.006 -E
– Degrease the cones of flywheel and crankshaft.
– Thoroughly oil the freewheel and mount the flywheel.
NOTE: Turn the reduction gear for easier mounting of the flywheel.
4
– Mount disk with the nut.
– Use the holding tool 5 to hold the flywheel and tighten the
hexagon nut with 150 Nm.
Repair manual KTM LC4
5
!
CAUTION
!
TO
AVOID DISTORTION OF THE CRANK WEB, NEVER MOUNT THE CRANKSHAFT
LOCKING BOLT TO TIGHTEN THE HEXAGON NUT OF THE FLYWHEEL.
– Insert 2 dowels into the housing.
– Apply silicone to both sealing surfaces and mount a new gasket.
– Mount the preassembled starter flange and use 4 bolts to fasten the
starter flange.
6-17D
Adjusting the pulse generator
3
2
1
– Turn the flywheel until the elevated section of the flywheel 1
coincides with the pulse generator 2.
– Use a feeler gauge to measure the distance between the pulse
generator and the flywheel.
Setpoint value: 0.75 mm (0.03 in) +/- 0.2 mm (0.008 in)
– If necessary undo the two bolts 3 and adjust the distance by
moving the pulse generator. When mounting the two bolts secure
them with Loctite 243.
– Insert 2 dowels.
– Apply silicone to both sealing surfaces and mount a new gasket.
– Mount ignition cover and tighten all bolts.
4
– Insert a new O-ring 4 into the groove of the starter cover and
fasten the starter cover with 3 bolts.
Mounting the ignition (SEM)
–
–
–
–
–
–
Block crankshaft with crankshaft locking bolt.
Place woodruff key in crankshaft.
Clean cones of crankshaft and flywheel and mount flywheel.
Fit spring washer and collar nut.
Tighten collar nut to 60 Nm.
Place the O-ring into the groove of the engine housing.
– Fit preassembled ignition cover and mount the 4 bolts but do not
tighten.
6-18D
Adjustment of ignition point (SEM)
NOTE: The ignition point is adjusted after the crankshaft locking bolt
has been mounted.
C
– Remove the plug at the ignition cover.
– Turn ignition cover so that the mark C on the stator and the mark
A on the flywheel are aligned.
– Tighten the 4 bolts of the ignition cover.
– Finally, mount the ignition cover plug.
A
NOTE: The 400 LC4 engine needs more preignition than the other LC4
engines. As all LC4 engines are equipped with the same ignition system,
the flywheel is provided with an additional mark (groove) for the 400
LC4 engine. The ignition adjustment procedure is exactly the same.
– In the 400 LC4 model the marking B (notch) must coincide with the
marking on the stator.
– In the 540 LC4, 620 LC4 and 640 LC4 model the marking A (2 mm
bore) must coincide with the marking on the stator.
A
B
Art.-Nr. 3.206.006 -E
2
Mounting the EPC wiring harness
– Put the wiring harness through the clip at the automatic tensioner
and connect all 3 cable lugs to the contact screws, making sure to
connect each cable to the corresponding screw:
– Connect the black/orange cable to contact screw 1.
– Connect the black/green cable to contact screw 2.
– Connect the black/blue cable to contact screw 3.
3
Repair manual KTM LC4
1
6-19D
Installing the ignition (Kokusan 4K-3)
– Block the crankshaft with the crankshaft locking bolt.
– Insert the woodruff key into the crankshaft.
– Clean the cone of the flywheel and the crankshaft and mount the
flywheel.
– Mount the spring washer and the collar nut (LH thread).
– Tighten the collar nut with 60 Nm.
– Insert the O-ring 1 into the groove in the engine housing.
1
– Mount the pre-assembled ignition cover. Insert the 4 bolts without
tightening them yet.
Adjusting the ignition point (Kokusan 4K-3)
NOTE: The ignition point is adjusted while the crankshaft locking bolt is
still twisted in.
A
C
B
– Remove the plug at the clutch cover.
– Turn the clutch cover until mark C on the pulse generator and mark
A or B, respectively, on the flywheel coincide.
NOTE: In 400 LC4 engines mark B must coincide with the mark on the
pulse generator.
In 620/660 LC4 engines mark A must coincide with the mark on the
pulse generator.
– Tighten the 4 bolts of the ignition cover.
– Finally, mount the plug.
A
B
6-20D
1
Mounting the oil hoses
– Mount the two oil hoses.
– Tighten banjo bolt 1 with 10 Nm and banjo bolt 2 with 15 Nm.
2
Mounting the clutch release lever
– To mount the clutch release lever 3, turn the clutch release shaft
clockwise as far as stop and fit the release lever as illustrated.
– Tighten clamp bolt 4.
3
4
Mounting the electric starter motor
– Slightly oil the O-ring on the flange of the electric starter motor.
– Mount the electric starter motor and fix it with 2 bolts 5.
Art.-Nr. 3.206.006 -E
5
Mounting the water hoses
Repair manual KTM LC4
– Mount the two water hoses and use the four hose clamps to fasten.
6-21D
up to model 2001
Pouring in engine oil
from model 2002 on
– Mount oil drain plug 1 with seal ring and tighten with 30 Nm.
– Mount the magnetic plug 2 and tighten with 20 Nm.
1
NOTE: A third plug was installed in the 660 SMC model. Tightening
torque: 20 Nm
1
2
2
– Remove the oil dipstick or the oil filler screw on the clutch cover and
add engine oil (see below for quality and viscosity). Remount the oil
dipstick or the oil filler screw.
!
CAUTION
!
– ONLY
–
–
USE HIGH-QUALITY OILS MEETING OR SURPASSING THE QUALITY
REQUIREMENTS OF JASO T903 MA (FOR SPECIFICATIONS SEE CONTAINERS).
INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE
ENGINE.
YOU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE
CRITERIA.
Oil capacity (up to model 2002) : 1.40 l
Oil capacity (from model 2003 on) : 1.50 l
JASO T903 MA
TEMPERATURE
0°C
32°F
5W/40
10W/50
Mounting the kickstarter and the shift lever
– Put the kickstarter onto the kickstarter shaft, then mount bolt 3
together with a new Schnorr lock washer 4 and tighten it.
– Put the V- seal ring 5 and the shift lever onto the shifting shaft.
– Mount bolt 6 together with 2 Nordlock discs 7 and washer 8.
– Adjust the stop rubber for the kickstarter so that it rests against the
kickstarter.
NOTE: As soon as the engine is assembled close all openings providing
access to the engine (intake port, exhaust port, water connections,
bleeding openings ...) with appropriate plugs to prevent small parts
from slipping into the interior of the engine during the further
installation process.
3
4
5
8
6
7
7-1D
7
ELECTRICAL
INDEX
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
ELECTRICAL – SUPER COMPETITION . . . . . . .
CHECKING THE VOLTAGE REGULATOR-RECTIFIER
CHECKING THE VOLTAGE REGULATOR . . . . . . . .
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . .
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. . . . .7-4
. . . . .7-4
. . . . .7-4
. . . . .7-4
ELECTRICAL – LC4 COMPETITION . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE NEUTRAL SWITCH . . . . . . . . . . . . . . . . . . . . .
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.7-5
.7-5
.7-5
.7-6
.7-6
.7-6
.7-7
.7-7
ELECTRICAL – LC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . . .7-9
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-12
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . .7-12
CHECKING THE DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-13
CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-14
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-14
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-16
EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
7-2D
INDEX
DISMOUNT / RENEW SOLENOID VALVE FOR EPC
CHECK OF SOLENOID VALVE FOR EPC . . . . . . . .
CONTROLLER OF THE EPC SYSTEM . . . . . . . . . . .
CHECK OF EPC SYSTEM MICROSWITCH . . . . . . .
REPLACING THE EPC SYSTEM MICROSWITCH . . .
CHECK OF IDLE SWITCH / CONTACT SCREWS . .
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. . . . . . . . . . . . .7-18
. . . . . . . . . . . . .7-18
. . . . . . . . . . . . .7-18
. . . . . . . . . . . . .7-19
. . . . . . . . . . . . .7-19
. . . . . . . . . . . . .7-19
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
ELECTRICAL – DUKE-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR
REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . .
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.7-20
.7-20
.7-20
.7-21
.7-21
.7-21
.7-22
.7-23
.7-24
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . . .7-24
CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-25
CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-26
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-26
IDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
SPARK PLUG CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
CHECKING THE SIDE STAND RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
CHECKING THE SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-29
ELECTRICAL – SXC ‘99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
CHECKING THE VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .7-30
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
7-3D
INDEX
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
ELECTRICAL – SC ‘99 . . . . . . . . . . . .
CHECKING THE VOLTAGE REGULATOR
CHECKING THE CAPACITOR . . . . . . . .
CHECKING THE IGNITION COIL . . . . . .
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.7-31
.7-31
.7-31
.7-31
ELECTRICAL – DUKE ‘99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . .7-33
REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34
ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-36
CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . . .7-36
CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-37
CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38
CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-38
TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-38
CHECKING THE IDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39
CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
SPARK PLUG CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
CHECKING THE SIDE STAND RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
CHECKING THE SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-41
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER
(FROM MODEL 2000 ON)
DYNAMIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE
STATIC IGNITION VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE
STATIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE
STATIC IGNITION VALUES 400/620/625 SC, 660 SMC . . . . . . . . . . . . .
STATIC GENERATOR VALUES 400/620/625 SC, 660 SMC . . . . . . . . . . .
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.7-42
.7-43
.7-45
.7-47
.7-49
CHECKING SPEEDOMETER AND SPEEDOMETER SENSOR . . . . . . . . . . . .7-51
7-4D
ELECTRICAL – SUPER COMPETITION
Checking the voltage regulator-rectifier
– Start the engine and switch on the low beam.
– Connect a voltmeter to the two terminals of the capacitor (red/white
cable = positive, brown cable = negative).
– Accelerate the engine to a speed of 5000 r.p.m. and read off the
voltage.
Nominal value: 14.0 - 15.0 V
If the reading significantly deviates from the nominal value above,
check the capacitor. If the capacitor is intact, replace the voltage
regulator-rectifier.
Checking the voltage regulator
The two voltage regulators are located under the right side cover at the
air filter box.
The voltage regulators are connected downstream of the switches. One
of the voltage regulators regulates only the brake light circuit, the other
regulates the circuit for the head light, the tail light, the speedometer
illumination and the horn.
Art Nr 320549-D
A defect voltage regulator can cause different kinds of trouble:
● No voltage in the circuit
In this case, the voltage regulator must be disconnected at idle speed.
The voltage regulator is defect if the power consumers now work
properly.
If the power consumers are still not supplied with power, the switch, the
wiring harness or the ignition system must be checked for defects.
1
● Excessive voltage in the circuit
The bulbs burn out.
Connect a voltmeter (yellow cable = positive, brown cable = negative)
to check the voltage. Start the engine and switch on the power
consumers.
At an engine speed of 3000 r.p.m, the voltage regulator must supply a
voltage of 12.0 - 14.0 V A.C. At higher engine speeds, the limit of 14 V
should not be exceeded either.
If the reading significantly deviates from the nominal value, replace the
voltage regulator.
Repair manual KTM LC4
Checking the capacitor
– Discharge the capacitor 1 by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +)
is made with a test lamp 1.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
!
!
CAUTION
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE
TO + TERMINAL.
7-5D
ELECTRICAL – LC4 COMPETITION
2
ignition
lock
ge-r
1
3
bl
ge
5
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.blue
.brown
.yellow
.grey
.green
.orange
.red
.pink
.black
.violet
.white
Charging system
1
2
3
4
5
Generator
Regulator-rectifier
Main fuse (20 A)
Battery (12V / 8 Ah)
Capacitor
Leakage inspection
The drop test must be performed before checking the voltage
regulator/rectifier
– Turn off the ignition and disconnect the ground wire from the
battery.
– Insert an amperemeter between the ground wire and the negative
pole of the battery.
Setpoint value: max. 1 mA
– Check for power consumers, should the measured value exceed the
indicated maximum value.
Example:
● defective voltage regulator-rectifier
● leak currents in the socket connectors, in the ignition lock or in the
starter relay.
0,00
7-6D
Removing the battery
1
– Remove the seat.
– Disconnect first the negative and then the positive pole of the
battery.
– Remove the bolts 1 and swing the battery support with the voltage
regulator-rectifier sideways.
– Remove the battery.
– When reinstalling the battery, connect the negative pole last.
!
!
CAUTION
FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW
THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER
SUPPLIED WITH THE BATTERY.
BATTERY.
MANUAL
Charging the battery
Art.-Nr. 3.206.006 -E
– Remove the battery and check the charging level. Use a voltmeter to
measure the voltage between the battery poles (off-load voltage).
– Accurate results can only be obtained if the battery has neither been
charged nor discharged during a period of 30 minutes preceding the
measuring.
– If the battery is empty, it can be recharged for a maximum period of
10 hours at 0.8 A and a maximum of 14.4 V.
!
CAUTION
!
– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR
– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE
CHARGING UNIT ON.
– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT
VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING
PROCESS.
– CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED
VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY
VALVES.
– AVOID QUICK CHARGING IF POSSIBLE.
off load voltage
Volt
charging level
%
charging time
0.8 A
>12.7
~12.5
~12.2
~12.0
~11.8
100
75
50
25
0
––
4h
7h
11 h
14 h
charging voltage
max.
14.4 V
Charging voltage / checking the voltage regulator-rectifier
NOTE: The values stated below apply only to fully charged batteries
(minimum charging level 90%).
Repair manual KTM LC4
– Start the engine and switch on the low beam.
– Connect a voltmeter to both battery connections.
– Accelerate the engine to a speed of 5000 rpm and read off the
voltage.
Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier
and the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.
7-7D
Checking the capacitor
– Pull main fuse out of the fuse holder.
– Discharge the capacitor 1 by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +)
is made with a test lamp 3.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
3
!
!
CAUTION
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE
TO + TERMINAL.
Checking the neutral switch
– Remove the chain cover.
– Connect one terminal of a test lamp to the positive pole of the
battery and the other to connection 1 of the neutral switch.
– The test lamp must light up when the transmission is switched to
neutral.
– The test lamp must go out as soon as a gear is put in.
1
7-8D
ELECTRICAL – LC4
CDI
2
ignition
lock
ge-r
s-r
3
r-s
ge
start
relay
5
4
Art.-Nr. 3.206.006 -E
br
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.white
Charging system
1
2
3
4
5
Generator
Regulator-rectifier
Main fuse (20 A)
Battery (12V / 8 Ah)
Capacitor
Leakage inspection
The drop test must be performed before checking the voltage
regulator/rectifier
– Turn off the ignition and disconnect the ground wire from the
battery.
– Insert an amperemeter between the ground wire and the negative
pole of the battery.
Repair manual KTM LC4
Setpoint value: max. 1 mA
– Check for power consumers, should the measured value exceed the
indicated maximum value.
Example:
● defective voltage regulator-rectifier
● leak currents in the socket connectors, in the ignition lock or in the
starter relay.
0,00
7-9D
Removing the battery
1
– Remove the seat.
– Disconnect first the negative and then the positive pole of the
battery.
– Remove the bolts 1 and swing the battery support with the voltage
regulator-rectifier sideways.
– Remove the battery.
– When reinstalling the battery, connect the negative pole last.
!
!
CAUTION
FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW BATTERY.
THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER MANUAL
SUPPLIED WITH THE BATTERY. ANY FAILURE TO OBSERVE THESE INSTRUCTIONS MAY
RESULT IN SEVERE INJURIES.
Charging the battery
– Remove the battery and check the charging level. Use a voltmeter to
measure the voltage between the battery poles (off-load voltage).
– Accurate results can only be obtained if the battery has neither been
charged nor discharged during a period of 30 minutes preceding the
measuring.
– If the battery is empty, it can be recharged for a maximum period of
10 hours at 0.8 A and a maximum of 14.4 V.
!
CAUTION
!
– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR.
– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE
CHARGING UNIT ON.
– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT
VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING
PROCESS.
– CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED
VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY
VALVES.
– AVOID QUICK CHARGING IF POSSIBLE.
off load voltage
Volt
charging level
%
charging time
0.8 A
>12.7
~12.5
~12.2
~12.0
~11.8
100
75
50
25
0
––
4h
7h
11 h
14 h
charging voltage
max.
14.4 V
Charging voltage / checking the voltage regulator-rectifier
NOTE: The values stated below apply only to fully charged batteries
(minimum charging level 90%).
– Start the engine and switch on the low beam.
– Connect a voltmeter to both battery connections.
– Accelerate the engine to a speed of 5000 rpm and read off the
voltage.
Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier
and the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.
7-10D
Checking the capacitor
– Pull main fuse out of the fuse holder.
– Discharge the capacitor 1 by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +)
is made with a test lamp 1.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
1
!
!
CAUTION
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE
TO + TERMINAL.
7-11D
ge-bl
10 A
3
ge-bl
2
ge-r
r
s
5
4
to EPC control
unit
o
ge
r-w
bl-w
20 A
9
M
1
2
3
4
5
6
7
8
9
bl .
br .
ge
gr .
g .
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v .
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Battery
Ignition lock
Emergency off switch
Auxiliary relay
Tip switch built in emergency off switch
Neutral switch
Clutch switch
Starter relay
Starter motor
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.white
6
br
G
7
g-s
1
ge
8
Electric Starter system
NOTE: The electric starter system is equipped with a safety mechanism.
Starting is possible only in the following conditions:
● ignition lock in position
or
● emergency OFF switch in position
● transmission set to idle, or clutch is pulled
Function of the electric starter system:
From the battery 1, battery voltage is supplied via the ignition lock 2
and the emergency OFF switch 3 to the coil of the auxiliary starter
relay 4 and the tip switch 5.
The contact of the auxiliary starter relay will enable starting only if at
least one of the following conditions is met :
● transmission is set to idle (idle switch 6 closed)
● clutch is pulled (clutch switch 7 closed)
If the tip switch 5 is actuated, the electric starter motor 9 is turned on
by way of the starter relay 8.
7-12D
Check start auxiliary relay
– Remove headlight mask and remove the start auxiliary relay.
1
– Connect the start auxiliary relay to a 12 V battery as shown in the
illustration.
– Use an ohmmeter to measure the continuity between the terminals
A and B.
A
Reading 0 Ω relay intact
Reading ∞ Ω relay defect
B
Checking the auxiliary starting relay for faultless operation
Art.-Nr. 3.206.006 -E
Preparation:
– Pull the auxiliary starter relay out of its holder.
– Connect an ohmmeter or a continuity tester to the cables of the
auxiliary starting relay (colors: red and red/white).
– Perform the tests in the order indicated below. The auxiliary starting
relay must respond in either of the following two cases:
2
● Put in a gear and slowly pull the clutch lever. The auxiliary starting
relay should respond when the lever is pulled approximately half of
the overall distance. If this is not the case, please check the clutch
switch. Keep an eye on the neutral control lamp while performing
this test. The neutral control lamp should not light up. If it lights up,
check the diode.
● Switch the transmission to neutral without previously pulling the
clutch. The auxiliary starting relay should now connect and be
tripped as soon as a gear is put in. If this is not the case, please
check the diode and the neutral switch.
Repair manual KTM LC4
NOTE: Connecting of the auxiliary starting relay is always accompanied
by a faint clicking sound. The ohmmeter or continuity tester indicates
continuity while the auxiliary starting relay is on.
Checking the diode
NOTE: Diodes conduct current only in the direction indicated by the
arrow, preventing the conduction of current in the opposite direction.
Two different kinds of diode defects can be distinguished:
– The diode conducts no current at all.
– The diode conducts current in both directions.
Diode defects can lead to different kinds of trouble, depending on the
type of defect.
NOTE: The diode is located in a 2-pole connector.
Checking for faultless operation:
– Remove the headlight mask.
– Pull the diode 2 out of the connector.
– Connect an appropriate ohmmeter to the diode and check for
continuity.
– Connect the ohmmeter in the opposite direction and check if the
diode prevents current conduction in the opposite direction.
7-13D
Checking the starter relay
– Remove the seat and the right side cover and disconnect the
combination connector 1 of the starter relay.
– Disconnect negative terminal at battery and the two cables at the
starter relay.
1
C
– Connect the starter relay to a 12 V battery as indicated in the
diagram.
– Check continuity between terminals C and D using an ohmmeter.
Reading: 0 Ω OK
Reading: ∞ Ω defect
NOTE: The response of the starter relay is accompanied by a faint
clicking sound.
D
Checking the electric starter motor
2
– Switch off the ignition.
– Disconnect the negative pole of the battery and remove the electric
starter motor.
– Connect the negative pole of a 12 V battery to the housing of the E
starter motor and briefly connect the positive pole of the battery to
connection 2 of the electric starter motor (use thick cables).
– The starter must turn as soon as the circuit is closed.
– If this is not the case, replace the starter motor.
7-14D
Checking the clutch switch
– Disconnect the clutch switch from the cable tree.
– Connect the ohmmeter to the 2-pole connector 2 (cable colors:
yellow/yellow) of the clutch switch and slowly pull the clutch lever.
– The switch must connect when the lever is pulled approximately half
of the overall distance.
2
Checking the tip switch and the emergency OFF switch
– Remove the headlight mask.
– Disconnect the 4-pole connector 3 of the tip switch/emergency OFF
switch from the cable tree.
– Use an ohmmeter and test both switches according to the table
below (please refer to the sketch for the configuration of the
connector).
– Then check all lines for ground contact.
3
Art.-Nr. 3.206.006 -E
Circuit
Emergency off switch
Emergency off switch
Tip switch
Tip switch
Position
operated
not operated
Condition
duct
no duct
duct
no duct
start
switch
emergenc
y off
switch
Trouble shooting in the electric starter system
Repair manual KTM LC4
When the starter motor fails to turn upon operation of the tip switch,
perform the following checks first:
●
●
●
●
●
●
●
●
Is the ignition lock in position
or
?
Is the emergency OFF switch position
?
Is the neutral control lamp on while the ignition is on?
Can the engine be started with the clutch pulled?
Is the battery charged?
Has the main fuse blown?
Has the fuse for startsystem and ignition blown?
Fuse for starter system and ignition has melted?
● Check the auxiliary starting relay
● Check the starter relay
● Check the electric starter motor
7-15D
3
4
to EPC-controlunit
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Battery
Main fuse (20 A)
Ignition lock
Emergency-off switch
Auxiliary relay
CDI
Pulse generator
Ignition coil
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Ignition system
From the battery 1, battery voltage is delivered via the main fuse 2,
through the activated ignition lock 3 and the activated emergency OFF
switch 4 to the CDI unit 6.
During each revolution of the crankshaft, the pulse generator 7
supplies a signal to the CDI unit 6. In the CDI unit, this signal is
processed so as to calculate the ignition point.
This ignition pulse is passed on to the ignition coil 8 (the ignition spark
is produced).
The ignition system is a digital high voltage capacitor ignition that
receives its power supply from the battery. Therefore, it works only with
an intact battery.
When the battery is discharged below the threshold level, the voltage
can, due to the starting process, drop below the minimum supply
voltage required by the ignition. In this case, turn off the light, and use
the kickstarter.
!
SAFE
CAUTION
!
AND FAULTLESS OPERATION OF THE DIGITAL IGNITION REQUIRES SPARK PLUG
CONNECTORS AND SPARK PLUGS WITH INTEGRATED RESISTANCE TYPE SUPPRESSORS.
7-16D
CDI unit
Check the cables and plug and socket connections of the CDI unit 1.
The CDI unit function can only be checked on an ignition test bench.
!
CAUTION
NEVER USE A COMMERCIAL MEASURING DEVICE
COMMERCIAL MEASURING DEVICES CAN DESTROY
COMPONENTS.
!
TO CHECK THE CDI UNIT.
HIGHLY SENSITIVE ELECTRONIC
1
Checking the ignition coil
2
– Disconnect all cables and remove the spark plug connector.
– Use an ohmmeter to measure the following values.
NOTE: The indicated setpoint values correspond to a temperature of
20° C.
Replace the ignition coil if the measured values deviate significantly
from the setpoint values.
MEASUREMENT
COLOURS
RESISTANCE
primary coil
blue/white – ground
0,425 – 0,575 Ω
secondary coil
blue/white – ignition wire
10,80 – 16,20 kΩ
Trouble shooting in the ignition system
Art.-Nr. 3.206.006 -E
Before checking the ignition system check:
●
●
●
●
●
●
if the ignition lock is in position
or
if the emergency off switch is in position
if the neutral control lamp is on
if the motorcycle can be started with the clutch pulled
if the battery is charged
the main fuse
Repair manual KTM LC4
Check if an ignition spark is produced when the starter is operated.
Proceed as follows:
– Pull off the spark plug connector.
– Disconnect the spark plug connector from the ignition cable.
– Hold the free end of the ignition cable approximately 5 mm from
ground.
– A strong spark should be visible when the electric starter is now
operated. If the battery level is low, turn off the light, and use the
kick starter.
– If a spark is visible, replace the spark plug connector.
– Twist out the spark plug and insert it into the spark plug connector.
– Connect the spark plug to ground. A strong spark should be visible
at the electrode when the electric starter is now operated. If this is
not the case, the spark plug connector or the spark plug is defect.
– If no spark is produced during the first test, perform the following
checks:
● Does the ignitionís power supply line (orange) carry battery voltage?
● If this is not the case, check the ignition lock, the emergency OFF
switch and, if applicable, the side stand relay as well as the
corresponding parts of the cable tree.
– If the ignition is sufficiently supplied with power and no spark is
produced, check:
● ground connection of CDI unit and ignition coil
● the cable between CDI unit and ignition coil
● pulse generator
● stator
● ignition coil
NOTE: The CDI unit can’t be tested with simple devices. It can only be
replaced. It can only be tested on an ignition test bench.
7-17D
4
10
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5
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Battery (12V / 8 Ah)
Main fuse (20 A)
Ignition lock
Fuse for ignition and start system
EPC-control unit
Ignition lock
Contact screw 2nd gear
Contact screw 3rd gear
Micro switch
Solenoid valve
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EPC system
Function:
From the battery 1, battery voltage is supplied to the EPC controller 5
via the main fuse 2, the activated ignition lock 3, and the fuse 4.
The blue/white cable leading to the ignition coil 6 provides an r.p.m.
signal to the EPC controller 5. Using this signal, the EPC controller will
then calculate the current speed.
When the throttle grip is opened all the way (microswitch 9 closes) at
a certain speed, the EPC controller will activate the solenoid valve bk,
provided that either the 2nd or the 3rd gear has been engaged.
By opening the solenoid valve bk, a dosed amount of fresh air will get
to the upper end of the slide membranes of the carburetor. This causes
the throttle slide to open slowly. Thereby, the operating noise of the
motorbike is reduced.
NOTE: If malfunctions develop in the EPC system, the EPC controller
can be unplugged. This will not cause damage to any other parts of the
motorcycle.
7-18D
Dismount / renew solenoid valve for EPC
– Remove seat, side covers, and tank with spoilers.
– Unplug the solenoid-valve connector.
– Disconnect the two hoses, and pull solenoid valve 1 upwards and
out of the holder.
1
– Insert new solenoid valve into the holder.
– Connect the two hoses, and plug in connector.
Check of solenoid valve for EPC
NOTE: When you turn on the ignition, the solenoid valve must open for
approx. 1 second. During this process, you can hear a slight clicking
noise.
– For checking, disconnect the 2-pole connector 2 at the solenoid
valve.
– Now, connect a 12V battery to both terminals of the solenoid valve.
– When closing the power circuit, a clicking noise must be audible in the
solenoid valve (the membrane opens).
2
– If you cannot hear any clicking noise, you have to replace the solenoid
valve.
Art.-Nr. 3.206.006 -E
Controller of the EPC system
NOTE: The controller 3 cannot be checked by means of standard
measuring methods.
3
If malfunctions develop in the EPC system, start by checking:
solenoid valve
microswitch
plug-and-socket connection 4 and cables
contact screws at engine
hose from magnetic valve to carburetor
– If the above components are okay, the controller has to be replaced.
!
BEFORE
CAUTION
!
Repair manual KTM LC4
CONNECTING THE CONTROLLER, IT IS ABSOLUTELY NECESSARY THAT YOU
TURN OFF THE IGNITION. OTHERWISE, MALFUNCTIONS IN THE ELECTRONIC SYSTEM
MAY DEVELOP.
4
7-19D
Check of EPC system microswitch
NOTE: The microswitch is arranged on the left side of the constantdepression carburetor in the area of the throttle valve. If the throttle
valve is opened all the way, the microswitch will close the power circuit.
– Remove seat and tank.
– Disconnect the 2-pole plug 2 of the microswitch.
– Connect an ohmmeter to both terminals of the microswitch.
– With the throttle valve closed, the ohmmeter must indicate zero
continuity.
– Open throttle valve all the way by twisting the throttle grip as far as
possible. In this case, you will hear a slight clicking noise of the
microswitch. In this position, the ohmmeter must indicate conductive
continuity.
2
Replacing the EPC system microswitch
– Remove seat and tank.
– Disconnect the microswitch plug.
– Remove the 2 screws 3, and take off the microswitch.
– Apply Loctite 243 to the threads of the two screws.
– Position the new microswitch, and fasten it with the two screws.
– Connect the plug, mount tank and seat.
3
Check of idle switch / contact screws
NOTE: The contact screw having the cable colors black/blue closes the
contact, when the 2nd gear is engaged.
The contact screw having the cable colors black/orange closes the
contact, when the 3rd gear is engaged.
The contact screw having the cable colors black/green closes the
contact, when the idle gear is engaged.
1
– Before you start with the check, disconnect the plug-and-socket
connection 1 to the EPC controller.
– For checking of the contact screws, connect a test lamp to the
positive terminal of the battery.
– Touch the connection of the central contact screw 6 with the test
probe. With the transmission set to idle, the test lamp has to be lit.
– When a gear is engaged, the test lamp must cease to be lit.
6
4
– Shift to 2nd gear, and touch the connection of the lower contact
screw 5 with the test probe. The test lamp must light up.
– With the transmission set to idle, the test lamp must not be lit.
– Shift to 3rd gear, and touch the connection of the upper contact
screw 4 with the test probe. The test lamp must light up.
– With the transmission set to idle, the test lamp must not be lit.
5
7-20D
ELECTRICAL – DUKE-E
CDI
2
ignition
lock
ge-r
1
3
s-r
start
relay
r-s
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5
4
tachometer
Art.-Nr. 3.206.006 -E
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Charging system
Repair manual KTM LC4
1
2
3
4
5
Generator
Regulator-rectifier
Main fuse (20 A)
Battery (12V / 8 Ah)
Capacitor
Leakage inspection
The drop test must be performed before checking the voltage
regulator/rectifier
– Turn off the ignition and disconnect the ground wire from the
battery.
– Insert an amperemeter between the ground wire and the negative
pole of the battery.
Setpoint value: max. 1 mA
0,00
– Check for power consumers, should the measured value exceed the
indicated maximum value.
Example:
● defective voltage regulator-rectifier
● leak currents in the socket connectors, in the ignition lock or in the
starter relay.
7-21D
Charging voltage / checking the voltage regulator-rectifier
NOTE: The values stated below apply only to fully charged batteries
(minimum charging level 90 %).
– Start the engine and switch on the low beam.
– Connect a voltmeter to both battery connections.
– Accelerate the engine to a speed of 5000 rpm and read off the
voltage.
Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier
and the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.
Removing the battery
1
1
– Remove the seat.
– Disconnect first the negative and then the positive pole of the
battery.
– Remove the bolts 1 and swing the battery support with the voltage
regulator-rectifier sideways.
– Remove the battery.
– When reinstalling the battery, connect the negative pole last.
!
CAUTION
!
FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW
THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER
SUPPLIED WITH THE BATTERY.
BATTERY.
MANUAL
Charging the battery
– Remove the battery and check the charging level. Use a voltmeter to
measure the voltage between the battery poles (off-load voltage).
– Accurate results can only be obtained if the battery has neither been
charged nor discharged during a period of 30 minutes preceding the
measuring.
– If the battery is empty, it can be recharged for a maximum period of
10 hours at 0.8 A and a maximum of 14.4 V.
!
CAUTION
!
– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR
– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE
CHARGING UNIT ON.
– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT
VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING
PROCESS.
– CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED
VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY
VALVES.
– AVOID QUICK CHARGING IF POSSIBLE.
off load voltage
Volt
charging level
%
charging time
0.8 A
>12.7
~12.5
~12.2
~12.0
~11.8
100
75
50
25
0
––
4h
7h
11 h
14 h
charging voltage
max.
14.4 V
7-22D
Checking the capacitor
– Pull main fuse out of the fuse holder.
– Discharge the capacitor by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +)
is made with a test lamp 1.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
1
!
!
CAUTION
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE
TO + TERMINAL.
7-23D
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Battery
Ignition lock
Emergency off switch
Auxiliary relay
Tip switch built in emergency off switch
Neutral switch
Clutch switch
Start relay
Starter motor
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Electric starter system
The system is equipped with a safety mechanism. Electric starting is only
possible when
● the ignition lock is in the position
● the emergency OFF switch is in the position
● the transmission is switched to neutral or the clutch is pulled.
Function of the electric starter system:
From the battery 1 the battery voltage is transmitted via the ignition
lock 2 and the emergency OFF switch 3 to the coil of the auxiliary
starting relay 4 and to the tip switch 5.
The contact of the auxiliary starting relay prevents starting unless at
least one of the following requirements is met :
● The transmission must be switched to neutral (neutral switch 6 is
closed).
● The clutch must be pulled (clutch switch 7 must be closed).
When the tip switch 5 is operated, the starter motor 9 is switched on
via the starter relay 8.
7-24D
Check start auxiliary relay
– Remove headlight mask and remove the start auxiliary relay (cable
colours red and red-white).
A
B
– Connect the start auxiliary relay to a 12 V battery as shown in the
illustration.
– Use an ohmmeter to measure the continuity between the terminals
A and B.
Reading 0 Ω relay intact
Reading ∞ Ω relay defect
Art.-Nr. 3.206.006 -E
Checking the auxiliary starting relay for faultless
operation
Preparation:
– Connect an ohmmeter or a continuity tester to the cables of the
auxiliary starting relay (colors: red and red/white).
– Perform the tests in the order indicated below. The auxiliary starting
relay must respond in either of the following two cases:
● Put in a gear and slowly pull the clutch lever. The auxiliary starting
relay should respond when the lever is pulled approximately half of
the overall distance. If this is not the case, please check the clutch
switch. Keep an eye on the neutral control lamp while performing
this test. The neutral control lamp should not light up. If it lights up,
check the diode with the cable colors yellow and green/black.
● Switch the transmission to neutral without previously pulling the
clutch. The auxiliary starting relay should now connect and be
tripped as soon as a gear is put in. If this is not the case, please
check the diode in the connector with the cable colors yellow and
green/black and the neutral switch.
Repair manual KTM LC4
NOTE: Connecting of the auxiliary starting relay is always accompanied
by a faint clicking sound. The ohmmeter or continuity tester indicates
continuity while the auxiliary starting relay is on.
7-25D
Checking the diodes
NOTE: Diodes conduct current only in the direction indicated by the
arrow, preventing the conduction of current in the opposite direction.
Two different kinds of diode defects can be distinguished:
– The diode conducts no current at all.
– The diode conducts current in both directions.
Diode defects can lead to different kinds of trouble, depending on the
type of defect.
NOTE: Both diodes are the same type and require the same testing
procedure. They are each located in a 2-pole connector and can be
identified by the color of the cables leading up to and away from the
respective connector.
Checking the diodes for faultless operation:
– Remove the headlight mask.
– Pull the diode to be tested out of the connector.
– Connect an appropriate ohmmeter to the diode and check for
continuity.
– Connect the ohmmeter in the opposite direction and check if the
diode prevents current conduction in the opposite direction.
Checking the clutch switch
– Disconnect the clutch switch from the cable tree.
– Connect the ohmmeter to the 2-pole connector 3 (cable colors:
yellow/yellow) of the clutch switch and slowly pull the clutch lever.
– The switch must connect when the lever is pulled approximately half
of the overall distance.
3
Checking the tip switch and the emergency off switch
– Remove the headlight mask.
– Disconnect the 4-pole connector 4 of the tip switch/emergency OFF
switch from the cable tree.
– Use an ohmmeter and test both switches according to the table
below (please refer to the sketch for the configuration of the
connector).
– Then check all lines for ground contact.
Circuit
Emergency off switch
Emergency off switch
Tip switch
Tip switch
4
starter
tip
switch
emergenc
y off
switch
Position
operated
not operated
Condition
duct
no duct
duct
no duct
7-26D
Checking the starter relay
– Remove the seat and the right side cover and disconnect the
combination connector 1 of the starter relay.
– Disconnect negative terminal at battery and the two cables at the
starter relay.
1
– Connect the starter relay to a 12 V battery as indicated in the
diagram.
– Check continuity between terminals C and D using an ohmmeter.
C
Reading: 0 Ω OK
Reading: ∞ Ω defect
NOTE: The response of the starter relay is accompanied by a faint
clicking sound.
D
Art.-Nr. 3.206.006 -E
Checking the electric starter motor
– Switch off the ignition.
– Disconnect the negative pole of the battery and remove the electric
starter motor.
– Connect the negative pole of a 12 V battery to the housing of the E
starter motor and briefly connect the positive pole of the battery to
connection 2 of the electric starter motor (use thick cables).
– The starter must turn as soon as the circuit is closed.
– If this is not the case, replace the starter.
2
Checking the neutral switch
Repair manual KTM LC4
– Remove the chain cover.
– Connect one terminal of a test lamp to the positive pole of the
battery and the other to connection 3 of the neutral switch.
– The test lamp must light up when the transmission is switched to
neutral.
– The test lamp must go out as soon as a gear is put in.
3
Trouble shooting in the electric starter system
When the starter motor fails to turn upon operation of the tip switch,
perform the following checks first:
●
●
●
●
●
●
Is the ignition lock switched to
?
Is the emergency OFF switch in the position
?
Is the neutral control lamp on while the ignition is on?
Can the engine be started with the clutch pulled?
Is the battery charged?
Has the main fuse blown?
● Check the auxiliary starting relay
● Check the starter relay
● Check the starter motor
7-27D
ge-bl
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0
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G
7
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2
3
4
5
6
7
8
9
Battery
Main fuse
Ignition lock
Emergency-off switch
Auxiliary relay
CDI
Pulse generator
Ignition coil
Side stand switch
Ignition system
From the battery 1 the battery voltage is conducted via the main fuse
2 through the ignition lock 3 and the emergency OFF switch 4,
which are both ON, to the side stand relay 5.
The side stand relay conducts the battery voltage to the CDI unit 6, if
at least one of the following requirements is met :
● The side stand is up (side stand switch closed).
● The transmission is switched to neutral (neutral switch closed).
● The clutch is pulled (clutch switch closed).
The pulse generator 7 transmits a signal to the CDI unit 6 upon every
rotation of the crankshaft. In the CDI unit, the ignition point is
computed from this signal.
The ignition pulse is transmitted to the ignition coil 8 (i.e. an ignition
spark is generated).
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.white
NOTE: The ignition system is a digital high voltage capacitor ignition
that receives its power supply from the battery. Therefore, it works only
with an intact battery.
When the battery is discharged below the threshold level, the voltage
can, due to the starting process, drop below the minimum supply
voltage required by the ignition.
!
SAFE
CAUTION
!
AND FAULTLESS OPERATION OF THE DIGITAL IGNITION REQUIRES SPARK PLUG
CONNECTORS AND SPARK PLUGS WITH INTEGRATED RESISTANCE TYPE SUPPRESSORS.
7-28D
CDI unit
Check the cables and plug and socket connections of the CDI unit 1.
The CDI unit function can only be checked on an ignition test bench.
!
CAUTION
NEVER USE A COMMERCIAL MEASURING DEVICE
COMMERCIAL MEASURING DEVICES CAN DESTROY
COMPONENTS.
!
TO CHECK THE CDI UNIT.
HIGHLY SENSITIVE ELECTRONIC
1
Check ignition coil
– Disconnect all cables and remove the spark plug connector.
– Use an ohmmeter to measure the following values.
NOTE: The indicated setpoint values correspond to a temperature of
20° C.
Replace the ignition coil if the measured values deviate significantly
from the setpoint values.
MEASUREMENT
COLOURS
RESISTANCE
primary coil
blue/white – ground
0,425 – 0,575 Ω
secondary coil
blue/white – ignition wire
10,80 – 16,20 kΩ
Spark plug connector
Art.-Nr. 3.206.006 -E
– Check the spark plug connector for cracks and fissures.
– Measure spark plug connector resistance.
Setpoint value: 3.0 – 7.5 kΩ
Checking the side stand relay
Repair manual KTM LC4
Preparation:
– Remove the seat, the right side cover and the headlight mask.
– Disconnect the power supply from the CDI (orange cable).
– To check the current status of the relay connect the orange cable
coming from the cable tree either to the positive line of a voltmeter
or to a test lamp.
– The negative line of the voltmeter or test lamp is connected to
ground.
– Switch on the ignition lock and the emergency OFF switch.
2
Perform the following tests in the order indicated below:
– The relay must connect in either of the following three cases:
● Put a gear in but do not pull the clutch. Slowly swing up the side
stand. When the side stand is approximately halfway up, the side
stand relay should respond. If this is not the case, please check the
relay, the side stand switch 2 as well as the corresponding parts of
the cable tree.
● With the side stand down and a gear put in, slowly pull the clutch
lever. The side stand relay should respond when the lever is pulled
approximately half of the overall distance. If this is not the case,
please check the diode in the connector with the yellow and the pink
cable and the neutral switch.
● With the side stand down and the clutch not pulled, switch the
transmission to neutral. The relay should connect when the
transmission is switched to neutral and be tripped when a gear is
put in. If this is not the case, please check the diode in the connector
with the yellow and the green/black cable and the neutral switch.
NOTE: Responding of the relay is accompanied by a faint clicking sound
and the CDI’s power supply is switched on. The voltmeter or the test
lamp indicates a battery voltage. After testing, reconnect the CDI unit’s
power supply (orange cable).
7-29D
Checking the side stand switch
2
– Disconnect the 2 connectors connecting the side stand switch 2
with the cable tree (below the tank).
– Connect an ohmmeter to the side stand cable.
– Slowly swing up the side stand.
– The switch must be open while the side stand is down.
– The side stand switch must connect when the side stand is
approximately halfway up.
– If this is not the case, replace the side stand switch.
!
CAUTION
NEVER SHORT-CIRCUIT THE SIDE STAND SWITCH SO AS TO BE
THIS WOULD DEACTIVATE THE IGNITION CUT-OFF WITH THE
!
ABLE TO DRIVE ON.
SIDE STAND DOWN,
AND YOUR MOTORCYCLE WOULD NO LONGER COMPLY WITH THE APPLICABLE
SAFETY STANDARDS.
NOTE: If the side stand is removed, for example when subsequently
installing a center stand, the two connectors of the cable tree that lead
to the side stand switch must also be connected.
Trouble shooting in the ignition system
Before checking the ignition system check
● if the ignition lock is in position
● if the emergency off switch is in the position
● if the neutral control lamp is on
● if the motorcycle can be started with the clutch pulled
● if the battery is charged
● the main fuse
Check if an ignition spark is produced when the starter is operated.
Proceed as follows:
– Pull the spark plug connector.
– Disconnect the spark plug connector from the ignition cable.
– Hold the free end of the ignition cable approximately 5 mm from
ground.
– A strong spark should be visible when the electric starter is now
operated. If the battery is discharged below the threshold level
required for electric starting, please use the kickstarter.
– If a spark is visible, replace the spark plug connector.
– Twist out the spark plug and insert it into the spark plug connector.
– Connect the spark plug to ground. A strong spark should be visible
at the electrode when the electric starter is now operated. If this is
not the case, the spark plug connector or the spark plug is defect.
– If no spark is produced during the first test, perform the following
checks:
● Does the ignition’s power supply line (orange) carry battery voltage?
● If this is not the case, check the ignition lock, the emergency off
switch and, if applicable, the side stand relay as well as the
corresponding parts of the cable tree.
– If the ignition is sufficiently supplied with power and no spark is
produced, check:
● ground connection of CDI unit and ignition coil
● the cable between CDI unit and ignition coil
● pulse generator
● stator
● ignition coil
7-30D
ELECTRICAL – SXC ‘99
Checking the voltage regulator-rectifier
– Start the engine and switch on the low beam.
– Connect a voltmeter to the two terminals of the capacitor (red/white
cable = positive, brown cable = negative).
– Accelerate the engine to a speed of 5000 r.p.m. and read off the
voltage.
Nominal value: 14.0 - 15.0 V
If the reading significantly deviates from the nominal value above,
check the capacitor. If the capacitor is intact, replace the voltage
regulator-rectifier.
Checking the capacitor
Repair manual KTM LC4
Art Nr 320549-D
3
– Discharge the capacitor by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +)
is made with a test lamp 3.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
!
CAUTION
!
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE
TO + TERMINAL.
7-30
ELECTRICAL – SC ‘99
Checking the voltage regulator (Kokusan)
A defect voltage regulator can cause different kinds of trouble:
● No voltage in the circuit
In this case, the voltage regulator must be disconnected at idle
speed. The voltage regulator is defect if the power consumers now
work properly.
If the power consumers are still not supplied with power, the switch,
the wiring harness or the ignition system must be checked for
defects.
● Excessive voltage in the circuit
The bulbs burn out. In this case the voltage regulator must be
replaced.
Checking the capacitor
– Discharge the capacitor 1 by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +)
is made with a test lamp 3.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
!
CAUTION
!
DISCHARGE THE CAPACITOR BEFORE AND AFTER
WHEN INSTALLING THE CAPACITOR, MAKE
3
EACH TEST.
SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE
TO + TERMINAL.
Check ignition coil
– Disconnect all cables and remove the spark plug connector.
– Use an ohmmeter to measure the following values.
NOTE: The indicated setpoint values correspond to a temperature of
20° C.
Replace the ignition coil if the measured values deviate significantly
from the setpoint values.
MEASUREMENT
COLOURS
RESISTANCE
primary coil
blue/white – ground
0,425 – 0,575 Ω
secondary coil
blue/white – ignition wire
10,80 – 16,20 kΩ
7-32D
ELECTRICAL – DUKE ‘99
CDI
2
ignition
lock
ge-r
1
3
s-r
start
relay
r-s
ge
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5
4
tachometer
Art.-Nr. 3.206.006 -E
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Charging system
1
2
3
4
5
Generator
Regulator-rectifier
Main fuse (20 A)
Battery (12V / 8 Ah)
Capacitor
Leakage inspection
The drop test must be performed before checking the voltage
regulator/rectifier.
– Turn off the ignition and disconnect the ground wire from the
battery.
– Insert an amperemeter between the ground wire and the negative
pole of the battery.
Repair manual KTM LC4
Setpoint value: max. 1 mA
– Check for power consumers, should the measured value exceed the
indicated maximum value.
Example:
● defective voltage regulator-rectifier
● leak currents in the socket connectors, in the ignition lock or in the
starter relay.
0,00
7-33D
Charging voltage / checking the voltage regulator-rectifier
NOTE: The values stated below apply only to fully charged batteries
(minimum charging level 90 %).
– Start the engine and switch on the low beam.
– Connect a voltmeter to both battery connections.
– Accelerate the engine to a speed of 5000 rpm and read off the
voltage.
Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier
and the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.
Removing the battery
– Remove the seat.
– Disconnect first the negative and then the positive pole of the
battery.
– Remove the bolts 1 and swing the battery support with the voltage
regulator-rectifier sideways.
– Remove the battery.
– When reinstalling the battery, connect the negative pole last.
1
!
CAUTION
!
FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW
THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER
SUPPLIED WITH THE BATTERY.
BATTERY.
MANUAL
Charging the battery
– Remove the battery and check the charging level. Use a voltmeter to
measure the voltage between the battery poles (off-load voltage).
– Accurate results can only be obtained if the battery has neither been
charged nor discharged during a period of 30 minutes preceding the
measuring.
– If the battery is empty, it can be recharged for a maximum period of
10 hours at 0.8 A and a maximum of 14.4 V.
!
CAUTION
!
– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR
– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE
CHARGING UNIT ON.
– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT
VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING
PROCESS.
– CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED
VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY
VALVES.
– AVOID QUICK CHARGING IF POSSIBLE.
off load voltage
Volt
charging level
%
charging time
0.8 A
>12.7
~12.5
~12.2
~12.0
~11.8
100
75
50
25
0
––
4h
7h
11 h
14 h
charging voltage
max.
14.4 V
7-34D
Checking the capacitor
– Pull main fuse out of the fuse holder.
– Discharge the capacitor by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative
terminal of the capacitor. The connection between the positive pole
of the battery and the positive terminal of the capacitor (marked +)
is made with a test lamp 1.
– When the power circuit is closed, the test lamp must begin to light
up. As capacitor charging increases, the brightness of the test lamp
must decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the
lamp capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
1
!
!
CAUTION
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE
CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE
TO + TERMINAL.
7-35D
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Battery
Ignition lock
Emergency off switch
Auxiliary relay
Tip switch built in emergency off switch
Neutral switch
Clutch switch
Start relay
Starter motor
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Electric starter system
The system is equipped with a safety mechanism. Electric starting is only
possible when
● the ignition lock is in the position
● the emergency OFF switch is in the position
● the transmission is switched to neutral or the clutch is pulled.
Function of the electric starter system:
From the battery 1 the battery voltage is transmitted via the ignition
lock 2 and the emergency OFF switch 3 to the coil of the auxiliary
starting relay 4 and to the tip switch 5.
The contact of the auxiliary starting relay prevents starting unless at
least one of the following requirements is met :
● The transmission must be switched to neutral (neutral switch 6 is
closed).
● The clutch must be pulled (clutch switch 7 must be closed).
When the tip switch 5 is operated, the starter motor 9 is switched on
via the starter relay 8.
7-36D
Check start auxiliary relay
– Remove headlight mask and remove the start auxiliary relay (cable
colours red and red-white).
A
B
– Connect the start auxiliary relay to a 12 V battery as shown in the
illustration.
– Use an ohmmeter to measure the continuity between the terminals
A and B.
Reading 0 Ω relay intact
Reading ∞ Ω relay defect
Art.-Nr. 3.206.006 -E
Checking the auxiliary starting relay for faultless
operation
Preparation:
– Connect an ohmmeter or a continuity tester to the cables of the
auxiliary starting relay (colors: red and red/white).
– Perform the tests in the order indicated below. The auxiliary starting
relay must respond in either of the following two cases:
● Put in a gear and slowly pull the clutch lever. The auxiliary starting
relay should respond when the lever is pulled approximately half of
the overall distance. If this is not the case, please check the clutch
switch. Keep an eye on the neutral control lamp while performing
this test. The neutral control lamp should not light up. If it lights up,
check the diode with the cable colors yellow and green/black.
● Switch the transmission to neutral without previously pulling the
clutch. The auxiliary starting relay should now connect and be
tripped as soon as a gear is put in. If this is not the case, please
check the diode in the connector with the cable colors yellow and
green/black and the neutral switch.
Repair manual KTM LC4
NOTE: Connecting of the auxiliary starting relay is always accompanied
by a faint clicking sound. The ohmmeter or continuity tester indicates
continuity while the auxiliary starting relay is on.
7-37D
Checking the diodes
NOTE: Diodes conduct current only in the direction indicated by the
arrow, preventing the conduction of current in the opposite direction.
Two different kinds of diode defects can be distinguished:
– The diode conducts no current at all.
– The diode conducts current in both directions.
Diode defects can lead to different kinds of trouble, depending on the
type of defect.
NOTE: Both diodes are the same type and require the same testing
procedure. They are each located in a 2-pole connector and can be
identified by the color of the cables leading up to and away from the
respective connector.
Checking the diodes for faultless operation:
– Remove the headlight mask.
– Pull the diode to be tested out of the connector.
– Connect an appropriate ohmmeter to the diode and check for
continuity.
– Connect the ohmmeter in the opposite direction and check if the
diode prevents current conduction in the opposite direction.
Checking the clutch switch
– Disconnect the clutch switch from the cable tree.
– Connect the ohmmeter to the 2-pole connector 3 (cable colors:
yellow/yellow) of the clutch switch and slowly pull the clutch lever.
– The switch must connect when the lever is pulled approximately half
of the overall distance.
3
Checking the tip switch and the emergency off switch
– Remove the headlight mask.
– Disconnect the 4-pole connector 4 of the tip switch/emergency OFF
switch from the cable tree.
– Use an ohmmeter and test both switches according to the table
below (please refer to the sketch for the configuration of the
connector).
– Then check all lines for ground contact.
4
Circuit
Emergency off switch
Emergency off switch
Tip switch
Tip switch
starter
tip
switch
emergenc
y off
switch
Position
operated
not operated
Condition
duct
no duct
duct
no duct
7-38D
Checking the starter relay
– Remove the seat and disconnect the combination connector 1 of
the starter relay.
– Disconnect negative terminal at battery and the two cables at the
starter relay.
1
– Connect the starter relay to a 12 V battery as indicated in the
diagram.
– Check continuity between terminals C and D using an ohmmeter.
C
Reading: 0 Ω OK
Reading: ∞ Ω defect
NOTE: The response of the starter relay is accompanied by a faint
clicking sound.
D
Art.-Nr. 3.206.006 -E
Checking the electric starter motor
– Switch off the ignition.
– Disconnect the negative pole of the battery and remove the electric
starter motor.
– Connect the negative pole of a 12 V battery to the housing of the E
starter motor and briefly connect the positive pole of the battery to
connection 2 of the electric starter motor (use thick cables).
– The starter must turn as soon as the circuit is closed.
– If this is not the case, replace the starter.
2
Checking the neutral switch
Repair manual KTM LC4
– Remove the chain cover.
– Connect one terminal of a test lamp to the positive pole of the
battery and the other to connection 3 of the neutral switch.
– The test lamp must light up when the transmission is switched to
neutral.
– The test lamp must go out as soon as a gear is put in.
3
Trouble shooting in the electric starter system
When the starter motor fails to turn upon operation of the tip switch,
perform the following checks first:
●
●
●
●
●
●
●
Is the ignition lock switched to
?
Is the emergency OFF switch in the position
?
Is the neutral control lamp on while the ignition is on?
Can the engine be started with the clutch pulled?
Is the battery charged?
Has the main fuse blown?
Has the fuse under headlight mask blown?
● Check the auxiliary starting relay
● Check the starter relay
● Check the starter motor
7-39D
ge-bl
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2
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1
2
3
4
5
6
7
8
9
Battery
Main fuse
Ignition lock
Emergency-off switch
Auxiliary relay
CDI
Pulse generator
Ignition coil
Side stand switch
Ignition system
From the battery 1 the battery voltage is conducted via the main fuse
2 through the ignition lock 3 and the emergency OFF switch 4,
which are both ON, to the side stand relay 5.
The side stand relay conducts the battery voltage to the CDI unit 6, if
at least one of the following requirements is met :
● The side stand is up (side stand switch closed).
● The transmission is switched to neutral (neutral switch closed).
● The clutch is pulled (clutch switch closed).
The pulse generator 7 transmits a signal to the CDI unit 6 upon every
rotation of the crankshaft. In the CDI unit, the ignition point is
computed from this signal.
The ignition pulse is transmitted to the ignition coil 8 (i.e. an ignition
spark is generated).
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NOTE: The ignition system is a digital high voltage capacitor ignition
that receives its power supply from the battery. Therefore, it works only
with an intact battery.
When the battery is discharged below the threshold level, the voltage
can, due to the starting process, drop below the minimum supply
voltage required by the ignition.
!
SAFE
CAUTION
!
AND FAULTLESS OPERATION OF THE DIGITAL IGNITION REQUIRES SPARK PLUG
CONNECTORS AND SPARK PLUGS WITH INTEGRATED RESISTANCE TYPE SUPPRESSORS.
7-40D
CDI unit
Check the cables and plug and socket connections of the CDI unit 1.
The CDI unit function can only be checked on an ignition test bench.
!
CAUTION
NEVER USE A COMMERCIAL MEASURING DEVICE
COMMERCIAL MEASURING DEVICES CAN DESTROY
COMPONENTS.
1
!
TO CHECK THE CDI UNIT.
HIGHLY SENSITIVE ELECTRONIC
Check ignition coil
– Disconnect all cables and remove the spark plug connector.
– Use an ohmmeter to measure the following values.
NOTE: The indicated setpoint values correspond to a temperature of
20° C.
Replace the ignition coil if the measured values deviate significantly
from the setpoint values.
MEASUREMENT
COLOURS
RESISTANCE
primary coil
blue/white – ground
0,425 – 0,575 Ω
secondary coil
blue/white – ignition wire
10,80 – 16,20 kΩ
Spark plug connector
Art.-Nr. 3.206.006 -E
– Check the spark plug connector for cracks and fissures.
– Measure spark plug connector resistance.
Setpoint value: 3.0 – 7.5 kΩ
Checking the side stand relay
Preparation:
– Remove the seat, the right side cover. Swing the headlight mask
forward.
– Disconnect the power supply from the CDI (orange cable).
– To check the current status of the relay connect the orange cable
coming from the cable tree either to the positive line of a voltmeter
or to a test lamp.
– The negative line of the voltmeter or test lamp is connected to
ground.
– Switch on the ignition lock and the emergency OFF switch.
Repair manual KTM LC4
Perform the following tests in the order indicated below:
– The relay must connect in either of the following three cases:
● Put a gear in but do not pull the clutch. Slowly swing up the side
stand. When the side stand is approximately halfway up, the side
stand relay should respond. If this is not the case, please check the
relay, the side stand switch 2 as well as the corresponding parts of
the cable tree.
● With the side stand down and a gear put in, slowly pull the clutch
lever. The side stand relay should respond when the lever is pulled
approximately half of the overall distance. If this is not the case,
please check the diode in the connector with the yellow and the pink
cable and the neutral switch.
● With the side stand down and the clutch not pulled, switch the
transmission to neutral. The relay should connect when the
transmission is switched to neutral and be tripped when a gear is
put in. If this is not the case, please check the diode in the connector
with the yellow and the green/black cable and the neutral switch.
2
NOTE: Responding of the relay is accompanied by a faint clicking sound
and the CDI’s power supply is switched on. The voltmeter or the test
lamp indicates a battery voltage. After testing, reconnect the CDI unit’s
power supply (orange cable).
7-41D
Checking the side stand switch
– Disconnect the 2 connectors connecting the side stand switch 2
with the cable tree (below the tank).
– Connect an ohmmeter to the side stand cable.
– Slowly swing up the side stand.
– The switch must be open while the side stand is down.
– The side stand switch must connect when the side stand is
approximately halfway up.
– If this is not the case, replace the side stand switch.
!
CAUTION
NEVER SHORT-CIRCUIT THE SIDE STAND SWITCH SO AS TO BE
THIS WOULD DEACTIVATE THE IGNITION CUT-OFF WITH THE
!
ABLE TO DRIVE ON.
SIDE STAND DOWN,
AND YOUR MOTORCYCLE WOULD NO LONGER COMPLY WITH THE APPLICABLE
SAFETY STANDARDS.
NOTE: If the side stand is removed, for example when subsequently
installing a center stand, the two connectors of the cable tree that lead
to the side stand switch must also be connected.
Trouble shooting in the ignition system
Before checking the ignition system check
● if the ignition lock is in position
● if the emergency off switch is in the position
● if the neutral control lamp is on
● if the motorcycle can be started with the clutch pulled
● if the battery is charged
● the main fuse and the fuse under the headlight mask
Check if an ignition spark is produced when the starter is operated.
Proceed as follows:
– Pull the spark plug connector.
– Disconnect the spark plug connector from the ignition cable.
– Hold the free end of the ignition cable approximately 5 mm from
ground.
– A strong spark should be visible when the electric starter is now
operated. If the battery is discharged below the threshold level
required for electric starting, please use the kickstarter.
– If a spark is visible, replace the spark plug connector.
– Twist out the spark plug and insert it into the spark plug connector.
– Connect the spark plug to ground. A strong spark should be visible
at the electrode when the electric starter is now operated. If this is
not the case, the spark plug connector or the spark plug is defect.
– If no spark is produced during the first test, perform the following
checks:
● Does the ignition’s power supply line (orange) carry battery voltage?
● If this is not the case, check the ignition lock, the emergency off
switch and, if applicable, the side stand relay as well as the
corresponding parts of the cable tree.
– If the ignition is sufficiently supplied with power and no spark is
produced, check:
● ground connection of CDI unit and ignition coil
● the cable between CDI unit and ignition coil
● pulse generator
● stator
● ignition coil
7-42D
DYNAMIC GENERATOR VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2)
Measuring conditions:
– remove seat (also side trim and left side cover for Racing model)
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– battery in a startable condition, not fully loaded (start several times for fully loaded battery)
Regulator rectifier output – measure the voltage with the measuring
leads of the peak voltage adapter directly on the poles of the vehicle
battery:
– unstressed and stressed for the entire speed range
Multimeter display: 14 volts +/- 1 volt
NOTE: The black measuring lead on the peak voltage adapter should be
applied to the ground (negative terminal).
Check the charge current – remove main fuse, apply the multimeter
measuring leads (without the peak voltage adapter) to both connectors
on the fuse carrier 1 and measure the current (set the multimeter DCA
to 10 amperes):
1
– Unstressed (no electric consumer switched on), engine running at
idle speed (1400 +/-50 rpm)
Art.-Nr. 3.206.006 -E
Multimeter display: 6 amperes +/- 0.1 ampere
– Stressed (light switched on, horn and brake actuated), engine
running at idle speed
Multimeter display: 0 amperes +/- 0.1 ampere
– Stressed (light switched on, horn and brake actuated), engine
running at increasing speed (up to 8000 rpm)
Repair manual KTM LC4
Multimeter display: 2 amperes +/- 0.1 ampere
7-43D
6
5
3
s–g
s–g
1
2
7-44D
STATIC IGNITION VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2)
Measuring conditions:
– cold engine
– seat, side trim and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– battery loaded, ignition switch to position 1 (without light)
– the gap between the rotor and pulse generator must be set to 0.75 mm
– compression release lever pulled
– kick the kick starter forcefully at least 5 times for each measurement
NOTE: Before performing a test with the peak voltage adapter, make
sure that the orange cable (battery voltage) is applied to the CDI unit
and the black and white/black cables are applied to the ground.
Check the pulse generator for an output signal – two-pin connector 1
with green and white cable colors (also see circuit diagram on opposite
page):
1
4
– Apply the red measuring lead of the peak voltage adapter to the
green cable and the black measuring lead to the white cable,
disconnect connector 1 to disconnect the CDI unit 2.
Multimeter display: 7 volts +/- 1 volt
– Same measurement with CDI unit connected
3
Multimeter display: 4 volts +/- 1 volt
Art.-Nr. 3.206.006 -E
Check the generator phase for detection of the direction of rotation
three-pin connector 3 with red/black and black/yellow cables (also see
circuit diagram on opposite page):
– Apply the red measuring lead of the peak voltage adapter to the
red/black cable and the black measuring lead to the black/yellow
cable, disconnect connectors 3 and 4
Multimeter display: 17 volts +/- 1 volt
– Same measurement with connectors 3 and 4 connected
Multimeter display: 12.5 volts +/- 0.5 volt
Check the primary voltage output for ignition coil control for output
voltage – one-pin connector 5 with blue/white cable (also see circuit
diagram on opposite page):
– Apply the red measuring lead of the peak voltage adapter to the
ground and the black measuring lead S to the blue/white cable, CDI
unit 2 and ignition coil 6 connected
Repair manual KTM LC4
5
S
Multimeter display: 220 volts +/- 10 volts
7-45D
7
8
9
3
s–g
s–g
7-46D
STATIC GENERATOR VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2)
Measuring conditions:
– cold engine
– seat, side trim and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– battery loaded, ignition switch to position 1 (without light)
– compression release lever pulled
– kick the kick starter forcefully at least 5 times for each measurement
Check the generator output for voltage between the following cable
colors
– three-pin connector 3 (also see circuit diagram on opposite page),
connectors 3 and 4 disconnected; this disconnects the regulator
rectifier 7 and the CDI unit:
4
3
– between black/yellow and red/black
– between black/yellow and yellow
– between red/black and yellow
Multimeter display: 17 volts +/- 1 volt
NOTE: The measuring leads of the peak voltage adapter can be
randomly applied.
Art.-Nr. 3.206.006 -E
Check generator output for voltage to ground – three-pin connector 3
(also see circuit diagram on opposite page), connectors 3 and 4
connected; this connects the regulatorl rectifier 7 and the CDI unit:
– between black/yellow and ground
– between yellow and ground
– between red/black and ground
Multimeter display: 12.5 volts +/- 0.5 volt
NOTE: The black measuring lead of the peak voltage adapter must be
applied to the ground.
Check regulator rectifier output voltage 8 - two-pin connector 9 with
cable colors red and black/white disconnected, connectors 3 and 4
connected (also see circuit diagram on opposite page):
– between red and black/white (ground)
7
Repair manual KTM LC4
9
Multimeter display: 13 volts +/- 0.5 volt
7-47D
5
4
2
1
3
7-48D
STATIC IGNITION VALUES 400/620/625 SC / 660 SMC (KOKUSAN 4K-3, 3C)
Measuring conditions:
– cold engine
– seat, right side trim and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– light switch turned off
– the gap between the rotor and pulse generator must be set to 0.75 mm
– compression release lever pulled
– kick the kick starter forcefully at least 5 times for each measurement
Check the pulse generator for an output signal – two one-pin
connectors 1 with green and red cable colors (also see circuit diagram
on opposite page):
1
1
– Apply the red measuring lead of the peak voltage adapter to the
green cable and the black measuring lead to the red cable,
disconnect both connectors 1 to disconnect the CDI unit 2
Multimeter display: 4.5 volts +/- 0.5 volt
– Same measurement with CDI unit connected
3
Multimeter display: 3 volts +/- 0.5 volt
NOTE: On 625 SC-models one two-pin connector is used instead of the
two one-pin connectors, the colors of the cable are the same.
Art.-Nr. 3.206.006 -E
Check the generator charging coil for ignition capacitor charge for an
output signal– two-pin connector 3 with black/red and red/white cable
colors (also see circuit diagram on opposite page):
– Apply the red measuring lead of the peak voltage adapter to the
black/red cable and the black measuring lead to the red/white cable,
disconnect connector 3 to disconnect the CDI unit 2
Multimeter display: 30 volts +/- 5 volts
– Same measurement with connectors CDI unit connected
Multimeter display: 180 volts +/- 10 volts
Check the primary voltage output 4 for ignition coil control (also see
circuit diagram on opposite page) for output voltage (blue/white cable
color):
– Apply the red measuring lead R of the peak voltage adapter to
ground and the black measuring lead S to the blue/white cable, CDI
unit 2 and ignition coil 5 connected
Repair manual KTM LC4
4
5
R
S
Multimeter display: 180 volts +/- 10 volts
7-49D
6
9
10
11
7-50D
STATIC GENERATOR VALUES 400/620/625 SC / 660 SMC (KOKUSAN 4K-3, 3C)
Measuring conditions:
– cold engine
– seat, right side trim and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– light switch turned off
– compression release lever pulled
– kick the kick starter forcefully at least 5 times for each measurement
Check the generator output 6 (also see circuit diagram on opposite
page) for voltage between the following cable colors:
– between yellow and brown (ground), connector 7 disconnected
Multimeter display: 15 volts +/- 1 volt
– between white and brown (ground), connector 8 disconnected
7
8
Multimeter display: 19 volts +/- 1 volt
– Repeat both measurements with connector 7 and 8 connected.
The measured values should be the same.
Art.-Nr. 3.206.006 -E
NOTE: The black measuring lead of the peak voltage adapter must be
applied to the ground.
Check regulator rectifier output voltage 9 (also see circuit diagram on
opposite page, cable colors yellow/red), regulator rectifier bk
connected, capacitor bl disconnected:
– between yellow/red and brown (ground)
Multimeter display: 14 volts +/- 1 volt
10
Repair manual KTM LC4
S
NOTE:
– The black measuring lead S of the peak voltage adapter must be
applied to the ground.
– The regulator rectifier bk is located on the right behind the side trim.
7-51D
Checking the speedometer sensor and the speedometer
(Adventure – from the 2002 model)
Checking the speedometer:
– Disconnect the connector 1 from the speedometer.
NOTE: The connector 1 is located under the cockpit covering.
1
– Switch on the ignition.
– Briefly connect pins 2 and 3 (cable colors black/brown and
black/orange) with a cable several times while you observe the speed
reading. If the speedometer is functioning correctly, the speed should
be indicated.
2
3
Checking the speedometer sensor:
NOTE: The measurement must be made with the ignition switched on
and the plug and socket connection connected.
1
– Use a digital multimeter to measure the voltage at the black cable on
connector 1 against the ground.
– Slowly turn the front wheel.
– The measured value should be over 4.5 volts when the wheel is
turned or less than 1 volt when the magnet on the front-wheel hub
is within the range of the speed sensor.
!
SINCE
CAUTION
!
YOU MUST MEASURE WITH THE CONNECTOR ATTACHED, MAKE SURE TO
CAREFULLY PUSH THE MEASURING TIPS ON THE MULTIMETER THROUGH THE SEALING
FROM THE CABLE SIDE AND NOT TO DAMAGE ANY PART OF THE CONNECTOR.
8-1D
FUEL SYSTEM
INDEX
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
MIKUNI BST 40
PART-LOAD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
FULL-LOAD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
CHECKING/ADJUSTING THE THROTTLE SENSOR . . . . . . . . . . . . . . . . . . .8-9
ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
ADJUSTING THE THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
CHECK FLOAT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
DELL’ORTO
DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD) . . . . . . .8-12
ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD) . . . . . . . . . .8-13
DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND) . . . . . . .8-16
ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND) . . . . . . . . . .8-18
DISASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS) . . . . . . .8-21
ASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS) . . . . . . . . .8-22
CHECK FLOAT LEVEL (DELL’ORTO 38 ND / 40 SD) . . . . . . . . . . . . . . . . .8-25
CHECKING AXIAL CLEARANCE OF FLOAT (DELL’ORTO 38 ND / 40 SD) . .8-25
ADJUST HOT START DEVICE (DELL’ORTO 40 SD) . . . . . . . . . . . . . . . . . .8-25
ADJUSTING THE THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26
ADJUSTING THE CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26
KEIHIN FCR 41
DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28
CHECKING THE CHOKE SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31
CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .8-31
CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31
CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .8-31
CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31
ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-32
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . . . . .8-35
CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . . . . .8-36
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . . . . .8-36
ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37
CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . . . . .8-38
8
8-2D
INDEX
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
KEIHIN FCR-MX 41
DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40
CHECKING THE CHOKE SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43
CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .8-43
CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43
CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .8-43
CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43
ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-44
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . . . . .8-47
CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . . . . .8-48
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . . . . .8-48
ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49
CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . . . . .8-49
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
8-3D
CARBURETOR - MIKUNI BST 40
8-4D
AIR
FUEL AIR MIXTURE
FUEL
Part-load system (Mikuni BST 40)
The part-load system supplies the engine with fuel while the throttle slide is closed or only slightly
opened.
From the float chamber the fuel enters the mixture pipe through the idling jet. There the fuel
mixes with the air that flows in through the idling air jet.
Then the fuel air mixture reaches the idle adjusting screw and the bypass bores through the
mixture pipe.
A certain amount of the fuel air mixture is sucked into the intake pipe through the bypass bores.
The remaining fuel air mixture is adjusted by the idle adjusting screw and enters the intake pipe
through the idling bore.
Art.-Nr. 3.206.006 -E
8-5D
AIR
FUEL AIR MIXTURE
FUEL
Repair manual KTM LC4
Full-load system (Mikuni BST 40)
When the throttle valve is opened the engine speed increases and the negative pressure in the
venturi pipe grows. The same negative pressure is transferred to the upper side of the slide
membrane and pulls the throttle slide upwards.
At the same time the fuel flows from the float chamber through the main jet into the needle jet.
There it mixes with the air flowing in through the main air jet. The result is a fuel air mixture.
Negative pressure causes this fuel air mixture to flow through the space between the needle jet
and the jet needle into the venturi pipe. There it meets the main air flow sucked in by the
engine.
The precise amount of the mixture released is adjusted in the needle jet. The space through which
the mixture passes changes depending on the position of the throttle slide.
Throttle slide in top position: large space
Throttle slide in bottom position: small space
8-6D
Disassembling the carburetor (Mikuni BST-40)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.
!
CAUTION
!
TO
PREVENT DAMAGING OF THE SLIDE MEMBRANE DO NOT APPLY COMPRESSED AIR
TO CLEAN THE CARBURETOR BEFORE REMOVING THE MEMBRANE.
– Remove the two screws 1 and take off the membrane cover.
– Remove the throttle stop.
1
– Take the throttle slide out of the carburetor together with the spring.
– Pull the jet needle 2 out of the throttle slide.
2
– Remove the 2 screws 3 and take off the float chamber together
with the gasket.
3
8-7D
– Take the entire float unit 1 out of the carburetor.
1
4
2
– Then remove the main jet 2 together with the distance bushing.
– Remove the idling jet 3.
– Twist the mixture adjusting screw 4 clockwise all the way in. Count
and write down the number of twists.
Twist out the mixture adjusting screw and remove it together with
the spring, the O-ring and the washer.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
3
5
– Use a screwdriver to push the needle jet 5 upwards out of the
carburetor.
– Clean all jets and blow them through with compressed air.
– Clean the carburetor housing and use compressed air to blow through
all ducts within the carburetor.
8-8D
Assembling the carburetor (Mikuni BST 40)
– Put the needle jet into the carburetor, making sure that the flat
portion A is located next to the jet needle.
A
3
– Put the distance bushing 1 onto the needle jet and mount the main
jet 2.
– Mount the spring, the washer and a new O-ring on the mixture
adjusting screw 3 and twist the mixture adjusting screw all the way
in.
– Then twist the mixture adjusting screw back out, applying the same
number of twists you have written down when disassembling the
device.
2
1
– Mount the idling jet 4.
4
– Insert the float unit 5 into the carburetor.
5
6
– Mount the float chamber together with a new gasket and tighten
both screws 6.
8-9D
– Mount the throttle slide, making sure that the membrane of the
throttle slide rests properly against the round wall of the carburetor
housing.
– Insert the spring into the throttle slide.
– Put the throttle stop 1 into the membrane cover.
NOTE: The throttle stop shown in the picture is fitted in a restricted
version.
1
2
Art.-Nr. 3.206.006 -E
2
– Mount the membrane cover and fasten it with the two screws 2.
Checking the throttle sensor (from model 2003 on)
NOTE: the adjustment must be made in a mounted condition with the
cable connected and the ignition switched on.
– Use a digital multimeter to measure the voltage between the black
and yellow cables at the connector 3 (CDI).
!
CAUTION
!
Repair manual KTM LC4
SINCE
YOU MUST MEASURE WITH THE CONNECTOR ATTACHED, MAKE SURE TO
CAREFULLY PUSH THE MEASURING TIPS ON THE MULTIMETER THROUGH THE SEALING
FROM THE CABLE SIDE AND NOT TO DAMAGE ANY PART OF THE CONNECTOR.
3
– Reading with closed throttle (neutral position): 0.88 +/- 0,075 volts
– Slowly open the throttle valve with the throttle grip, the measured
voltage should increase uniformly up to the full load reading.
–
Reading with fully opened throttle grip (full throttle position):
3,88 +/- 0,1 volts.
Adjusting the throttle sensor
– Loosen the screw on the throttle sensor 4 and turn the throttle
sensor until you reach the reading for the neutral position.
– Tighten the screw on the throttle sensor.
4
8-10D
Adjust idling speed
NOTE: Warm up the engine before adjusting the idle speed.
Use the adjusting screw 1 to adjust the basic position of the throttle
valve and, thus, the idle speed. Turning in clockwise direction will
increase the idling speed, turning in counterclockwise direction will
reduce the idling speed. Normal idling speed 1400 - 1500 rpm.
1
Adjusting the throttle cable
3-5 mm
2
3
4
A play of 3-5 mm must at any time be left in the throttle cables. To
check the play of the throttle cables, first push back the protective cap
2 on the throttle twist grip. Now it should be possible to lift the outer
sleeve of one of the two cables 3-5 mm off the adjusting screw 4
before resistance is felt. The play of the throttle cables can be adjusted,
if necessary, using the two adjusting screws.
For this purpose, undo counter nut 3 and turn the adjusting screw until
the desired play is achieved. Then tighten the counter nut and replace
the protective cap.
After adjusting the throttle cables turn the handlebar all the way to the
left and to the right while the engine is still running. The idle speed
should not change.
Check float level
Take off the float chamber, press down the float frame and hold
carburator as shown in the picture. The float 5 mooves downwards.
5
Turn carburator slowly until the float moves towards the carburator. In
this position the edge of the float 6 must be parallel to the sealing
surface of the carburator 7.
!
CAUTION
!
IF
YOU HOLD ON TURNING THE CARBURATOR, THE FLOAT WILL PRESS AGAINST THE
SPRING OF THE NEEDLE VALVE AND A CORRECT CHECK IS NOT POSSIBLE. IN THAT
CASE THE CARBURATOR IS TO BE TURNED BACK AND THE CHECK MUST BE DONE
TWICE.
If the two edges are not parallel, correction can be done by bending the
lever of the needle valve. At the end a check is necessary again.
6
7
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
8-11D
CARBURETOR – DELL’ORTO PHM 40 SD
8-12D
Disassembling the carburetor (Dell’Orto PHM 40 SD)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.
– Remove the two screws and pull the carburetor cover out of the
carburetor together with the throttle slide.
– Wrap the throttle slide in a clean piece of cloth and put it onto the
air filter box.
– Undo screw bk and take the starting piston out of the carburetor.
10
– Remove the plug 1 together with the seal ring and take off the float
chamber.
1
2
– Remove the main jet 2, the main jet holder 3 and the baffle 4.
– Twist out the starting jet 5.
4
3
5
6
– Remove the idling jet 6 together with the idle mixture pipe below.
– Twist out the needle jet 7.
7
– Pull out the pin 8 and remove the float.
– Remove the entire needle valve 9 together with the gasket behind.
8
9
8-13D
– Twist the mixture adjusting screw 1 clockwise all the way in,
counting and writing down the number of twists. Twist out the
mixture regulating screw and remove it together with the spring, the
washer and the O-ring.
3
– Twist the adjusting screw 2 clockwise all the way in, counting and
writing down the number of twists. Twist out the adjusting screw
and remove it together with the spring, the O-ring and the washer.
1
2
– Remove screw 3, and take off the hose connection together with
the fuel filter 4.
3
– Clean all jets and other components and blow them through with
compressed air.
– Clean the carburetor housing and use compressed air to blow
through all ducts within the carburetor.
– Check all gaskets for damage and exchange them, if necessary.
4
Assembling the carburetor (Dell’Orto PHM 40 SD)
Art.-Nr. 3.206.006 -E
– Put the spring, the washer and the O-ring onto the mixture adjusting
screw 1 and twist the mixture adjusting screw all the way in.
– Twist out the mixture adjusting screw, applying the same number of
twists previously written down during the disassembly of the device.
– Put the spring, the washer and the O-ring onto the adjusting screw
2 and twist the adjusting screw all the way in.
– Twist out the adjusting screw, applying the same number of twists
previously written down during the disassembly of the device.
– Insert the fuel filter into the carburetor. Properly position the hose
connection and mount screw 3 together with the seal ring.
Repair manual KTM LC4
3
1
2
– Insert the seal ring into the carburetor bore and mount the needle
valve 5.
5
8-14D
– Position the float and mount the pin 1. When mounting the float
make sure that the needle valve properly engages with the float.
Check by moving the float upwards: the needle valve must move
with the float.
1
– Mount the idling mixture pipe and the idling jet 2.
– Mount the needle jet 3.
2
3
6
– Position the baffle 4 and fasten it with the main jet holder 5.
– Mount and tighten the main jet 6.
– Mount and tighten the starting jet 7.
4
5
7
Check the O-ring 8 in the float chamber for proper fit.
8
9
– Position the float chamber and fasten it with the plug 9. Do not
forget the seal ring.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
8-15D
CARBURETOR – DELL’ORTO PHM 38 ND
8-16D
Disassembling the carburetor (Dell’Orto PHM 38 ND)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.
– Remove the two screws and pull the carburetor cover out of the
carburetor together with the throttle slide.
– Wrap the throttle slide in a clean piece of cloth and put it onto the
air filter box.
– Undo screw and take the starting piston out of the carburetor.
– Remove the plug 1 together with the seal ring and take off the float
chamber.
1
– Remove the main jet 2, the main jet holder 3 and the baffle 4.
– Twist out the starting jet 6.
– Twist out the return valve 5.
2
3
4
5
6
– Remove the idling jet 8 together with the idle mixture pipe below.
– Twist out the needle jet 7.
8
7
– Pull out the pin 9 and remove the float.
– Remove the entire needle valve bk together with the gasket behind.
9
10
8-17D
– Twist the mixture adjusting screw 1 clockwise all the way in,
counting and writing down the number of twists. Twist out the
mixture regulating screw and remove it together with the spring, the
washer and the O-ring.
– Twist the adjusting screw 2 clockwise all the way in, counting and
writing down the number of twists. Twist out the adjusting screw
and remove it together with the spring, the O-ring and the washer.
1
2
– Remove screw 3, and take off the hose connection together with
the fuel filter.
3
Art.-Nr. 3.206.006 -E
– Twist out the jet holder 4 together with the accelerating jet 5.
4
5
– Remove the 3 screws 6 and take off the entire pump housing 7
together with the gasket.
Repair manual KTM LC4
7
6
8
!
CAUTION
!
– DO NOT DAMAGE THE MEMBRANE WHEN REMOVING THE PUMP HOUSING.
REMOVE THE MEMBRANE BEFORE CLEANING THE PUMP HOUSING.
– ADJUSTMENT SCREW 8 IS FACTORY CALIBRATED AND MUST NOT BE TURNED.
– Clean all jets and other components and blow them through with
compressed air.
– Clean the carburetor housing and use compressed air to blow
through all ducts within the carburetor.
– Check all gaskets for damage and exchange them, if necessary.
8-18D
Assembling the carburetor (Dell’Orto PHM 38 ND)
– Position the pump housing 1 together with the gasket and fasten
them with the 3 screws. Make sure that the membrane is properly
positioned in the pump housing.
1
2
– Put the seal ring onto the jet holder 3 and mount the jet holder
together with the accelerating jet 4. The flat section of the
accelerating jet must face backwards.
3
4
– Insert the fuel filter into the carburetor. Position the hose connection
and mount screw 5 together with the seal ring.
5
7
– Put the spring, the washer and the O-ring onto the mixture adjusting
screw 6 and twist the mixture adjusting screw all the way in.
– Twist out the mixture adjusting screw, applying the same number of
twists previously written down during the disassembly of the device.
– Put the spring, the washer and the O-ring onto the adjusting screw
7 and twist the adjusting screw all the way in.
– Twist out the adjusting screw, applying the same number of twists
previously written down during the disassembly of the device.
6
– Insert the seal ring into the carburetor bore and mount the needle
valve 8.
8
8-19D
– Position the float and mount the pin 1. When mounting the float
make sure that the needle 2 valve properly engages with the float.
Check by moving the float upwards: the needle valve must move
with the float.
1
2
– Mount the idling mixture pipe and the idling jet 4.
– Mount the needle jet 3.
4
3
–
–
–
–
Art.-Nr. 3.206.006 -E
7
6
Position the baffle 5 and fasten it with the main jet holder 6.
Mount and tighten the main jet 7.
Mount and tighten the starting jet 8.
Mount the return valve 9.
5
8
9
Check the O-ring bk in the float chamber for proper fit.
Repair manual KTM LC4
10
– Position the float chamber and fasten it with the plug bl. Do not
forget the seal ring.
11
8-20D
CARBURETOR – DELL’ORTO VHSB 38 QS
8-21D
Disassembling the carburetor (Dell’Orto VHSB 38 QS)
NOTE: Before commencing to disassemble the carburetor make sure
that your workplace is clean and large enough to properly arrange all
carburetor components before you.
– Open the cap and pull the carburetor cover out of the carburetor
together with the throttle slide.
– Wrap the throttle slide in a clean piece of cloth and put it onto the
air filter box.
– Undo the screw and pull the entire cold-starting device out of the
carburetor.
– Remove the three screws 1 and take off the float chamber together
with the gasket.
– Take the two floats out of the carburetor.
– Take the perforated bushing off the baffle.
1
Art.-Nr. 3.206.006 -E
2
– Remove the main jet 2 and the baffle 3.
– Twist out the starting jet 4 and the idling jet 5.
3
5
4
– Pull out pin 6 and remove the float arm 7.
Repair manual KTM LC4
7
6
– Remove the entire needle valve 8 together with the seal ring
behind.
8
8-22D
– Twist out the needle jet 1.
1
– Twist the mixture adjusting screw 2 clockwise all the way in,
counting and writing down the number of twists. Twist out the
mixture regulating screw and remove it together with the spring, the
washer and the O-ring.
3
– Twist the adjusting screw 3 clockwise all the way in, counting and
writing down the number of twists. Twist out the adjusting screw
and remove it together with the spring.
2
– Remove plug 5 together with the seal ring and take off the fuel
filter 4.
– Clean all jets and other components and blow them through with
compressed air.
– Clean the carburetor housing and use compressed air to blow
through all ducts within the carburetor.
4
– Check all gaskets for damage and exchange them, if necessary.
5
Assembling the carburetor (VHSB 38 QS)
– Put the spring, the washer and the O-ring onto the mixture adjusting
screw 2 and twist the mixture adjusting screw all the way in.
– Twist out the mixture adjusting screw, applying the same number of
twists previously written down during the disassembly of the device.
3
2
– Put the spring, the washer and the O-ring onto the adjusting screw
3 and twist the adjusting screw all the way in.
– Twist out the adjusting screw, applying the same number of twists
previously written down during the disassembly of the device.
– Insert the fuel filter 4 into the plug 5 and mount the plug together
with the seal ring.
4
5
8-23D
– Mount the needle jet 1.
– Insert the seal ring into the carburetor bore and mount the needle
valve 2.
1
2
– Position the float arm 3 and mount pin 4.
3
4
– Mount the idling jet 5 and the starting jet 6.
– Position the baffle 7 and fasten it with the main jet 8.
Art.-Nr. 3.206.006 -E
8
7
6
5
– Put the perforated bushing 9 onto the baffle and mount the gasket.
Repair manual KTM LC4
9
– Insert the two floats bk into the float chamber and mount the float
chamber.
10
8-24D
main jet
jet needle
jet needle
idling jet
throttle valve
mixture regulating screw
idle adjusting screw
Idling range – A
Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting
screw 2. Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed
is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.
The throttle stop screw is used to adjust the basic position of the throttle. The mixture control screw is used to control the idle
mixture which arrives at the engine via the idle system. Turning it clockwise will reduce the amount of gasoline (lean mixture),
turning it counterclockwise will increase the amount of gasoline (rich mixture).
TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:
1 Turn in mixture control screw up to the stop, and turn it back out by 1.5 turns
2 Warm up the engine
3 Use throttle stop screw to adjust normal idling speed (1400-1500 r.p.m.)
4 Turn mixture control screw slowly clockwise until idling speed starts to decrease. Memorize this position, and turn mixture
control screw slowly counterclockwise until the idling speed will decrease again. Adjust the point of the highest idling speed
between these two positions. (The highly competitive user will make his adjustment 1/4 turn leaner because his engine will
heat up more in competitive use).
NOTE: If you fail to obtain a satisfying result by following the procedure described above, an incorrectly dimensioned idling
nozzle may be the cause. In case:
a) the mixture control screw has been screwed in up to the stop without causing any change in rotational speed, a smaller
idling jet has to be installed;
b) the engine dies when the mixture control screw is still open by 2 turns, a larger idling jet needs to be selected;
Naturally, in cases of jet changes, you have to start your adjusting work from the beginning.
5 Now, use the slide stop screw to adjust the desired idling speed
6 In cases of greater changes in outside temperature and extremely different altitudes, the idling speed should be readjusted.
Opening up – B
Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good
idling-speed and part-throttle setting, the engine sputters when the throttle is fully opened and develops its full power not
smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float
needle is leaking.
Part-throttle range – C
Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum partthrottle setting is controlled by the idling setting in the lower range and by the main jet in the upper range.
Full throttle range – D
Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the
new spark plug is found to have a very bright or white coating after a short distance of riding flat out, a larger main jet is
required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one.
Basic information on carburetor wear
As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause
carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10000 kilometers (6000 miles).
8-25D
Mixture too rich:
Too much fuel in proportion to air
2
1
Mixture too lean:
Not enough fuel in proportion to air
Check float level (Dell’Orto PHM 38ND / 40SD)
Stand the carburettor diagonally at about 60° so that the spring in the
float needle valve is not pressed together. In this position, the edge of
the float should be parallel with the float bowl sealing surface (see
illustration).
60°
Checking axial play of float (Dell’Orto PHM 38ND / 40SD)
Art.-Nr. 3.206.006 -E
For proper functioning of the float, there must be an axial play of 0.8
mm (0,03 in). If necessary, slightly abrade and deburr lateral float guide.
0,8 mm
Adjust hot start device (Dell’Orto PHM 40SD)
If the hot start button was removed when cleaning the carburetor,
readjust the hot start device.
Install carburetor and adjust idling as discribed above. Then unlock nut
1, press in hot start device 2 and adjust engine rev with adjusting
screw 3 to 2000-2500 rpm. Tighten locking nut.
Repair manual KTM LC4
3
1
2
8-26D
Adjusting the throttle cable
There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable.
To check this, move back the protective cover 1 on the throttle grip.
You must be able to lift the outer covering of the cable 3-5 mm from
the adjusting screw 2, until resistance is felt.
To adjust, loosen the counter nut 3 and turn the adjusting screw
accordingly. Finally tighten counter nut and slide the protective cover
back on.
3-5 mm
3
2
1
Adjusting the choke cable
5
2 mm
4
At the choke cable, there must always exist a play of approx. 2 mm (0.1
in). To check this, push choke lever fully forward and pull protective
cover 4 from the adjuster piece 5. Now, it must be possible to lift the
outer covering of the cable by approx. 2 mm from the adjuster piece
until feeling a resistance. If necessary, loosen counter nut and readjust
play by turning the adjuster piece. Tighten counter nut, and slide on
protective cover.
Adjusting the choke cable
The choke cable must have a play of approximately 2 mm at all times.
To check the play turn the knob 6 into the initial position. Now it
should be possible to lift the exterior case of the choke cable
approximately 2 mm from the supporting surface of the choke knob
before the upward movement is blocked by resistance.
2 mm
6
7
To adjust, remove the seat and the gastank, push the protective cover
upwards, loosen the counter nut and turn the adjustment screw 7
accordingly. Turn the adjustment screw clockwise for more play or
anticlockwise for less play.
Tighten the counter nut, replace the protective cover and mount the
gas-tank and the seat.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
8-27D
CARBURATOR - KEIHIN FCR 41
8-28D
Disassembling the carburetor
NOTE: Before you start disassembling the carburetor, you should look
for a clean work place. It should offer you enough space to lay out all
individual components of the carburetor in perfect order.
– Dismount the carburetor and remove any coarse dirt.
1
– Remove the wire clip 1 and pull the ventilation hoses out of the
carburetor.
– Disconnect the hose 2.
– Loosen the 2 screws 3 and dismount all ventilation hoses from the
carburetor.
3
3
2
– Remove the 2 screws 4 and dismount the slide cover together with
its gasket.
4
– Remove the screw 5 and take the jet needle out of the throttle
valve.
– Remove the screw 6.
5
6
8-29D
– Now, pull the cable disc approx. 5 mm outward and turn it until the
throttle valve can be lifted out of the carburetor and detach the
rollers 1 at the throttle valve.
– Take the throttle valve together with the 4 rollers 2 and the valve
paddle out of the carburetor.
2
NOTE: When you turn the cable disc, it must not be blocked by the
stop bolt (see photo). Otherwise, pull the shaft further outward.
1
– Turn the carburetor around, remove the 3 screws and remove the
cover of the accelerator pump.
NOTE: When dismounting the cover, watch out for the spring and the
sealing rings as they may get lost easily.
– Remove the 2 sealing rings, the spring and the diaphragm from the
pump housing.
Art.-Nr. 3.206.006 -E
– Remove the screw and dismount the float chamber.
– Unhitch the push rod 3 of the accelerator pump and dismount it.
3
– Take the plastic part 4 off the needle jet.
– Loosen the screw 5, pull out the float hinge pin 6 and dismount
the float together with the float needle valve.
4
6
Repair manual KTM LC4
5
– Remove the screw 7 and use pliers to carefully extract the seat of
the float needle valve from the carburetor.
– Turn out the idling jet 8, the starting jet 9 and the needle jet
together with the main jet bk.
11
9
8
10
7
– Turn in the mixture control screw bl down to the stop, count the
number of turns and write it down.
– Turn out the mixture control screw and dismount it together with the
spring, the washer, and the O-ring.
NOTE: The spring, the washer, and the O-ring will usually remain in the
bore. These parts can be removed with the help of compressed air.
8-30D
– Remove the screw 1 and dismount the throttle-valve sensor 2.
When unfastening the screw, be sure to watch out for the
bushing 3.
4
3
NOTE: To dismount the throttle-valve sensor, always remove the screw
1. After the screw 4 was loosened, the throttle-valve sensor must be
adjusted again.
1
2
– Remove the screw and the clip together with the bushing and pull
the connection piece 5 out of the carburetor.
5
6
– Remove the 2 screws and take the intake trumpet together with the
O-ring 6 off the carburetor.
– Unscrew the idle-air jet 7 and the main air jet 8.
– Thoroughly clean all jets and other parts and blow compressed air
through them.
– Clean the carburetor housing and blow compressed air through all
ducts in the carburetor.
7
8
– Check all gaskets for damage and, if necessary, replace them.
8-31D
Checking the choke slide
It must be easy to actuate the choke slide.
The piston 1 of the choke slide must not have any pronounced score
marks or deposits.
1
Checking the accelerator pump
Check the membranes for cracking or brittleness.
Check gaskets for damage.
Check if the bores 2 are unobstructed.
2
2
Checking the jet needle
Art.-Nr. 3.206.006 -E
Check the jet needle for bending and wear.
Checking the float needle valve
Repair manual KTM LC4
Check the sealing surface of the needle valve for notches.
There must not be any dirt between valve seat and float needle.
Checking the throttle valve
4
3
Check the throttle valve paddles 3 for damage.
The rollers 4 at the throttle valve must be easy to turn and must not
have any flat spots.
8-32D
Assembling the carburetor
– Mount the idle-air jet 1 and the main air jet 2.
– Place the O-ring 3 in the groove and secure the intake trumpet to
the carburetor by means of the 2 screws.
3
2
1
– Insert the fuel connection 4 into the carburetor and secure it with
the clip.
NOTE: In the mounted state, the connection piece must be easy to
turn.
4
– Mount the choke slide 5 and actuate it several times, checking
whether it can be moved smoothly. Besides, check whether the
choke locks properly.
5
– Thread the spring, the washer and the O-ring onto the mixture
control screw 6 and screw the mixture control screw in as far as it
will go.
– Now, unscrew the mixture control screw the number of turns written
down during disassembly.
6
NOTE: Basic setting see technical spezifications.
8
– Mount idling jet 7, starting jet 8 and needle jet together with main
jet 9.
7
9
– Insert the needle jet bk into bore and secure it by means of the screw
bl.
11
10
8-33D
– Position the float, mount the float hinge pin and secure it by means
of the screw.
– Check the float level.
– Stick the plastic component 1 on the needle jet.
1
– Engage the push rod 2 of the accelerator pump at the lever.
2
Art.-Nr. 3.206.006 -E
– Mount the float chamber and at first secure it with only 1 screw.
When positioning the float chamber, make sure that the push rod 2
of the accelerator pump slides into the bore.
2
Repair manual KTM LC4
5
3
– Place the membrane 3 with the labeling facing upwards and the
spring into the pump housing.
– Place the O-ring 4 into the groove. Secure the sealing ring 5 with
some grease in the cover and fasten the cover by means of 3 screws.
4
6
– Turn the cable disc and push the throttle valve into the carburetor
such that the rollers 6 engage the throttle valve (see photo). Push
the throttle valve all the way into the carburetor.
– Turn the cable disc several times and while doing so check whether
the throttle valve moves smoothly.
8-34D
– Coat the thread of the screw 1 with Loctite 243 and mount the
screw, however, do not tighten it yet.
– Push the slide pin 2 inward. At the same time, push the slide lever
3 to the extreme right and tighten the screw 1.
2
1
3
– Now, the distances A on the left and on the right should be
identical. Then, turn the cable disc and check if the throttle valve
moves smoothly.
– Mount the jet needle and secure it with the screw 4.
A
A
4
– Position the slide cover together with its gasket and fasten it by
means of the 2 screws 5.
5
– Secure the ventilation hoses with the 2 screws 6 of the float
chamber and connect the hose 7.
6
6
7
– Insert the 2 hose connections into the bores and fasten them with
the retaining clip 8.
8
8-35D
– Mount the throttle valve sensor such that the flat spot at the
carburetor engages the groove of the throttle valve sensor and
secure it by means of the screw.
Adjusting the position of the throttle valve sensor
1
2
NOTE: Before checking the position of the throttle valve sensor, you
have to adjust the idle speed correctly.
– Disengage the plug-and-socket connection of the throttle valve
sensor.
– Connect a multimeter (measuring range Ω x 1k) to the blue (+) and
the black (-) cable of the throttle valve sensor and measure the
throttle valve resistance.
– Now, multiply this value by 0.15. This yields the adjustment value for
the throttle valve sensor.
Example:
throttle valve sensor resistance (bl/s) = 5 kΩ
throttle valve sensor resistance (ge/s) =
5 kΩ x 0.15 = 750 Ω ± 50 Ω
Art.-Nr. 3.206.006 -E
– Connect the multimeter (measuring range Ωx100) to the yellow (+)
and the black (-) cable of the throttle valve sensor and measure the
throttle valve sensor resistance with the throttle grip closed.
According to the above example, this value should be 750 Ω ± 50 Ω.
– If the value measured does not correspond to the desired value,
loosen the screw 1 and turn the throttle valve sensor 2 until the
instrument displays the desired value.
– Secure the throttle valve sensor in this position by fastening the
screw and check the value once more.
– Connect the throttle valve sensor to the wiring harness.
bl
bl
ge
ge
Repair manual KTM LC4
s
s
8-36D
Checking the throttle valve sensor
NOTE: The following measurement must be taken at a component
temperature of approx. 20°C.
– Open the plug-and-socket connection of the throttle valve sensor.
– Connect a multimeter (measuring range Ω x 1k) to the blue (+) and
the black (-) cable of the throttle valve sensor.
throttle valve sensor resistance: 4 - 6 kΩ
bl
bl
– Now, connect the multimeter to the yellow (+) and the black (-)
cable of the throttle valve sensor.
– As you open the throttle grip slowly, the resistance must change
evenly.
ge
throttle valve sensor resistance: 0-5 kΩ ±1 kΩ
(while opening the throttle grip)
ge
s
bl = blue
ge = yellow
s = black
s
Dismounting and installing the throttle valve sensor
– Disconnect the plug-and-socket connection of the throttle valve
sensor and remove the bolt 1.
– Take the throttle valve sensor off the carburetor.
1
– When mounting the throttle valve sensor, make sure that the flat
spot at the throttle valve pin 2 engages the groove on the throttle
valve sensor.
– Mount the bolt, however, do not yet tighten fully and adjust the
position of the throttle valve sensor. Secure the bolt with
Loctite 243.
2
8-37D
Adjust idling
Idling adjustment of the carburetor strongly affects the engine’s starting
behavior. That is, an engine whose idling speed is adjusted correctly will
be easier to start than one whose idling speed has not been adjusted
correctly.
1
2
2
The idle speed is controlled by means of the adjusting wheel 1 and the
mixture control screw 2. The adjusting wheel is used to adjust the basic
setting of the slide. The mixture control screw is used to control the idle
mixture which arrives at the engine by way of the idle system.
Clockwise turning reduces the fuel quantity (lean mixture),
counterclockwise turning increases the fuel quantity (rich mixture).
TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:
1 Turn in mixture control screw 2 up to the stop, and turn it back out
to the basic position (see technical data engine)
2 Warm up the engine
3 Use the adjusting wheel 1 to set the normal idle speed (1400 - 1500
rpm).
4 Turn mixture control screw 2 slowly clockwise until idling speed
starts to decrease. Memorize this position, and turn mixture control
screw slowly counterclockwise until the idling speed will decrease
again. Adjust the point of the highest idling speed between these
two positions. If, in the course of this procedure, the speed
undergoes a relatively high increase, reduce the idle speed to a
normal level and repeat the procedure specified in 4. Serious
competitive racers will choose a setting approx. 1/4 turn (clockwise)
leaner than this ideal value because their engine will heat up more
when used in competitions.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
NOTE: If you fail to obtain a satisfying result by following the procedure
described above, an incorrectly dimensioned idling nozzle may be the
cause.
a) If the mixture control screw has been screwed in up to the stop
without causing any change in rotational speed, a smaller idling jet
has to be installed;
b) If the engine dies when the mixture control screw is still open by
2 turns, a larger idling jet needs to be selected;
Naturally, in cases of jet changes, you have to start your adjusting
work from the beginning.
5 Then, use the adjusting wheel to set the desired idle speed.
6 In cases of greater changes in outside temperature and extremely
different altitudes, the idling speed should be readjusted.
8-38D
Adjusting the mixture control screw
The mixture control screw is difficult to reach. For this reasons, we have
created an appropriate special tool 590.29.034.000.
Introduce the special tool into the bore at the carburetor bottom. Press
the tool slightly upward and turn the adjusting wheel 1 until the tool
engages the slot of the mixture control screw 2.
Now, you can go about adjusting the screw. Marks were provided on
the adjusting wheel, making it easier to keep track of the turns.
1
2
Checking the float level (float height)
For this purpose, dismount the carburetor and remove the float
chamber. Hold the carburetor in a slanted position such that the float
will abut the float needle valve but not compress it (see photo).
Now, use a sliding caliper to measure the distance H between the
casing edge and the float's upper edge.
The float height H is to be 9 mm.
If the float height does not correspond to the desired value, check the
float needle valve and, if necessary, replace it.
H
If the float needle valve is correct, you can adjust the float height by
bending of the float lever 3.
3
Mount the float chamber, install the carburetor, and adjust the idle
speed.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
8-39D
CARBURETOR - KEIHIN FCR-MX 41
8-40D
Disassembling the carburetor Keihin FCR - MX 41
NOTE: Before you start disassembling the carburetor, you should look
for a clean workplace. It should offer you enough space to lay out all
individual components of the carburetor in perfect order.
– Dismount the carburetor and remove any coarse dirt.
– Loosen both bolts 1 and remove all of the vent hoses from the
carburetor.
1
1
– Remove both bolts 2 and remove the slide cover and gasket from
the carburetor.
2
2
– Remove screw 3 and pull the jet needle out of the throttle slide.
– Remove screw 4.
3
4
5
– Pull the throttle slide arm up and take the throttle slide roller 5 and
the slide shim out of the carburetor.
8-41D
– Turn the carburetor around, remove the 3 screws and remove the
cover of the accelerator pump.
NOTE: When dismounting the cover, watch out for the spring and the
sealing rings as they may get lost easily.
– Remove the 2 sealing rings, the spring and the diaphragm from the
pump housing.
– Remove the screws on the float chamber and remove the housing.
Art.-Nr. 3.206.006 -E
2
– Pull out the float hinge pin 1 and remove the float together with
the float needle valve.
– Remove the main jet 2.
1
7
4
Repair manual KTM LC4
6
– Remove the screw 3 and use pliers to carefully extract the seat of
the float needle valve from the carburetor.
– Screw out the idling jet 4, the starting jet 5 and the needle jet 6.
– Turn in the mixture control screw 7 down to the stop, count the
number of turns and write it down.
– Turn out the mixture control screw and dismount it together with the
spring, the washer, and the O-ring.
NOTE: The spring, the washer, and the O-ring will usually remain in the
bore. These parts can be removed with the help of compressed air.
5
3
8-42D
– Remove bolts 1 and the throttle sensor 2.
2
1
NOTE: the throttle sensor should only be dismounted if defective. If the
bolts 1 are loosened, the throttle sensor must be adjusted again.
1
– Remove screw 3 and pull the connecting piece out of the
carburetor.
3
4
5
6
– Remove the 2 screws and take the intake trumpet together with the
O-ring 4 off the carburetor.
– Unscrew the idle-air jet 5 and the main air jet 6.
– Thoroughly clean all jets and other parts and blow compressed air
through them.
– Clean the carburetor housing and blow compressed air through all
the ducts in the carburetor.
– Check all gaskets for damage and, if necessary, replace them.
8-43D
Checking the choke slide and hot start knob
Choke slide:
The choke slide must be easy to actuate .
The piston 1 of the choke slide must not have any pronounced score
marks or deposits.
1
Hot start knob:
The hot start knob must be easily actuated.
The piston on the hot start knob may not have any scores or deposits.
Checking the accelerator pump
Check the membranes for cracking or brittleness.
Check gaskets for damage.
Check if the bores 2 are unobstructed.
2
2
Checking the jet needle
Art.-Nr. 3.206.006 -E
Check the jet needle for bending and wear.
Checking the float needle valve
Repair manual KTM LC4
Check the sealing surface of the needle valve for notches.
There must not be any dirt between the valve seat and the float needle.
Checking the throttle valve
3
4
The rollers 3 at the throttle valve must be easy to turn and must not
have any flat spots.
Check the throttle valve paddles 4 for damage.
8-44D
Assembling the carburetor Keihin FCR-MX 41
3
1
– Mount the idle-air jet 1 and the main air jet 2.
– Place the O-ring 3 in the groove and secure the intake trumpet to
the carburetor by means of the 2 screws.
2
– Insert the fuel port in the carburetor and fix with screw 4.
NOTE: In the mounted state, the connection piece must be easy to
turn.
4
– Mount the choke slide 5, the hot start knob 6 and actuate several
times, checking for smooth operation. Also make sure the choke and
the hot start knob lock into place.
5
6
– Thread the spring, the washer and the O-ring onto the mixture
control screw 7 and screw the mixture control screw in as far as it
will go.
– Now, unscrew the mixture control screw the number of turns written
down during disassembly.
7
8
NOTE: See the Technical Specifications for the basic carburetor setting.
10
– Mount idling jet 8, starting jet 9 and needle jet together with main
jet bk.
9
– Insert the needle valve seat bl in the bore and fix with screw bm.
12
11
8-45D
– Position the float and the float needle valve and mount the float
hinge pin 1.
– Check the float level (see page 8-21).
1
– Mount the float chamber and the gasket, position the bracket for the
adjustment screw 2 and fix the float chamber with the screws 3.
NOTE: When positioning the float chamber, make sure that the push
rod 4 of the accelerator pump slides into the bore.
2
3
4
– Place the membrane 5 with the labeling facing upwards and the
spring into the pump housing.
– Place the O-ring 6 into the groove. Secure the sealing ring 7 with
some grease in the cover and fasten the cover by means of 3 screws.
Art.-Nr. 3.206.006 -E
5
7
6
Repair manual KTM LC4
– Mount the throttle valve sensor such that the flat spot at the
carburetor engages the groove of the throttle valve sensor and
secure it by means of the bolt.
8
9
– Pull up the throttle slide arm, push the throttle slide together with
roll 8 and the slide shim into the carburetor so that the rolls 9
engage in the throttle slide (see illustration).
– Check the throttle slide for smooth operation.
8-46D
– Apply Loctite 243 to the screw 1 and tighten.
– Mount the jet needle and fix with the screw 2.
2
1
– Position the slide cover with the gasket and fasten with the 2 screws
3.
3
3
– Fix the vent hoses on the float chamber with the 2 bolts 4.
4
4
8-47D
Adjusting the position of the throttle valve sensor
2
1
NOTE: Before checking the position of the throttle valve sensor, you
have to adjust the idle speed correctly.
– Disengage the plug-and-socket connection of the throttle valve
sensor.
– Connect a multimeter (measuring range Ω x 1k) to the blue (+) and
the black (-) cable of the throttle valve sensor and measure the
throttle valve resistance.
– Now, multiply this value by 0.15. This yields the adjustment value for
the throttle valve sensor.
1
Example:
Throttle valve sensor resistance (bl/s) = 5kΩ
Throttle valve sensor resistance (ge/s) =
5 kΩ x 0.15 = 750 Ω ± 50 Ω
– Connect the multimeter (measuring range Ωx100) to the yellow (+)
and the black (-) cable of the throttle valve sensor and measure the
throttle valve sensor resistance with the throttle grip closed.
According to the above example, this value should be 750Ω ± 50Ω.
– If the value measured does not correspond to the desired value,
loosen the 2 bolts 1 and turn the throttle valve sensor 2 until the
instrument displays the desired value.
– Secure the throttle valve sensor in this position by fastening the bolts
and check the value once more.
– Connect the throttle valve sensor to the wiring harness.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
bl
bl
ge
ge
s
bl = blue
ge = yellow
s = black
s
8-48D
Checking the throttle valve sensor
NOTE: The following measurement must be taken at a component
temperature of approx. 20°C.
– Open the plug-and-socket connection of the throttle valve sensor.
– Connect a multimeter (measuring range Ω x 1k) to the blue (+) and
the black (-) cable of the throttle valve sensor.
Resistance of throttle valve sensor: 4 - 6 kΩ
bl
bl
– Now, connect the multimeter to the yellow (+) and the black (-)
cable of the throttle valve sensor.
– As you open the throttle grip slowly, the resistance must change
evenly.
ge
Resistance of throttle valve sensor: 0-5 kΩ ±1 kΩ
(while opening the throttle grip)
ge
s
s
bl = blue
ge = yellow
s = black
Dismounting and installing the throttle valve sensor
1
– Disconnect the plug-and-socket connection of the throttle valve
sensor and remove the bolts 1.
– Take the throttle valve sensor off the carburetor.
1
– When mounting the throttle valve sensor, make sure that the flat
spot at the throttle valve pin engages the groove on the throttle
valve sensor.
– Mount the 2 bolts, however, do not yet tighten them fully and adjust
the position of the throttle valve sensor. Secure the 2 bolts with
Loctite 243.
8-49D
CARBURETOR – Adjust idling (Keihin FCR-MX 41)
Idling adjustment of the carburetor strongly affects the engine’s starting
behavior. That is, an engine whose idling speed is adjusted correctly will
be easier to start than one whose idling speed has not been adjusted
correctly.
The idle speed is controlled by means of the adjusting wheel 1 and the
mixture control screw 2. The adjusting wheel is used to adjust the basic
setting of the slide. The mixture control screw is used to control the idle
mixture which arrives at the engine by way of the idle system.
Clockwise turning reduces the fuel quantity (lean mixture),
counterclockwise turning increases the fuel quantity (rich mixture).
TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:
1 Turn in mixture control screw 2 up to the stop, and turn it back out
to the basic position (see technical date-engine)
2 Warm up the engine
3 Use the adjusting wheel 1 to set the normal idle speed (1400 1500 rpm).
4 Turn mixture control screw 2 slowly clockwise until idling speed
starts to decrease. Memorize this position, and turn mixture control
screw slowly counterclockwise until the idling speed decreases again.
Adjust the point of the highest idling speed between these two
positions. If, in the course of this procedure, the speed undergoes a
relatively high increase, reduce the idle speed to a normal level and
repeat the procedure specified in 4. Serious competitive racers will
choose a setting approx. 1/4 turn (clockwise) leaner than this ideal
value because their engine will heat up more when used in
competitions.
NOTE: If you fail to obtain a satisfying result by following the
procedure described above, an incorrectly dimensioned idling nozzle
may be the cause. If:
a) the mixture control screw has been screwed in up to the stop
without causing any change in rotational speed, a smaller idling jet
has to be installed;
b) the engine dies when the mixture control screw is still open by
2 turns, a larger idling jet needs to be selected.
Naturally, in cases of jet changes, you have to start your adjusting
work from the beginning.
5 Then, use the adjusting wheel to set the desired idle speed.
6 In cases of greater changes in the outside temperature and extremely
different altitudes, the idling speed should be readjusted.
1
Art.-Nr. 3.206.006 -E
2
3
Basic information on carburetor wear
As a result of engine vibrations, the throttle valve, jet needle, and
needle jet are subjected to increased wear. This wear may cause the
carburetor to malfunction (e.g., overly rich mixture). Therefore, these
parts should be replaced after 200 hours.
Adjusting the mixture control screw
Especially on the EXC models, accessing the mixture control screw is
difficult. For this reasons, we have created an appropriate special tool.
Repair manual KTM LC4
Introduce the special tool on the mixture control screw 2 at the
carburetor bottom. Press the tool slightly upward and turn the adjusting
wheel 3 until the tool engages the slot of the mixture control screw.
Now, you can go about adjusting the screw. Marks were provided on
the adjusting wheel, making it easier to keep track of the turns.
Checking the float level (float height)
4
For this purpose, dismount the carburetor and remove the float
chamber. Hold the carburetor in a slanted position such that the float
will abut the float needle valve but not compress it.
In this position, the edge of the float should be parallel with the
float chamber sealing surface (see illustration).
If the float height does not correspond to the desired value, check the
float needle valve and, if necessary, replace it.
If the float needle valve is o.k., you can adjust the float height by
bending the float lever 4.
Mount the float chamber, install the carburetor, and adjust the idle
speed.
9-1D
TROUBLE SHOOTING
INDEX
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
TROUBLE SHOOTING (SX, SXC, SC, SMC) . . . . . . . . . . . . . . . . . . . .9-2
TROUBLE SHOOTING (LC4 COMPETITION) . . . . . . . . . . . . . . . . . . .9-4
TROUBLE SHOOTING (LC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
9
9-2
TROUBLE SHOOTING – SX, SXC, SC, SMC
TROUBLE
Art.-Nr. 3.206.006 -E
Engine will not start
Repair manual KTM LC4
Engine will not idle
Engine does not rev high
REMEDY
CAUSE
Operating error
Switch on ignition, switch on emergency OFF switch, open
fuel tap, tank fuel, do not use choke i.e. the hotstart device.
Pay attention to starting off information (see driving
instructions).
Fuel supply interrupted
Close fuel tap, loosen fuel hose at carburettor, lead into a
basin and open fuel tap,
– if fuel leaks out, clean carburettor
– if no fuel leaks out, check tank ventilation, i.e. clean fuel
tap
Flooded engine
See driving instructions
Sooty or wet spark plug
Clean or replace spark plug
Electrode gap too large
Adjust spark plug electrode gap to 0,6 mm
Spark plug connector or spark plug
faulty
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate kickstarter, a strong
spark must be produced at the spark plug
– If no spark is produced, loosen spark plug cap from ignition
cable, hold about 5 mm from ground and actuate
kickstarter
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
If
connector
oxidates
generator to ignition coil
from
Remove fuel tank, clean connector and treat with contact
spray
Short circuit cable scored in wiring
harness, ignition lock, emergency OFF
switch or short circuit button faulty
Remove fuel tank, draw off blue/black cable from orange
cable of ignition coil and check spark.
– If a spark is produced, seek fault in short circuit current
The plug connection of the CDIunit, the pulse generator or the
ignition coil has oxydized
Remove the seat, the right side cover and the fuel tank.
Clean the plug connection and treat it with contact spray
Water in short emergency OFF switch
Remove 2-pole connector located underneath the headlight
mask, treat emergency OFF switch with contact spray
Water in carburettor or jets blocked
Dismount and clean carburettor
Carburettor does not fit in properly
at intake flange
Check if carburettor is fitted in correctly
Idling jet blocked
Dismount carburettor and clean jets
Adjusting screws on carburettor
uncorrect adjusted
Adjust carburettor
Ignition system faulty
Check ignition system
Carburettor fuel level too high
because float needle valve is dirty
or worn out
Dismount carburettor and check if worn out
Loose carburettor jets
Tighten jets
Electronical ignition timing faulty
Check ignition system
9-3D
REMEDY
TROUBLE
CAUSE
Engine will not reach full
power
Fuel supply partically interrupted or
carburettor dirty
Clean and check fuel system as well as carburettor
Float is not tight, or no axial play
Replace or abrade the float
Air filter very dirty
Clean or replace air filter
Exhaust leaking or blocked
Check if exhaust is damaged, replace glas fibre yarn in
exhaust silencer
Valve gap to small
Adjust valve gap
Loss of compression because hand
decompressor has no play
Check setting of the hand decompression cable
Electronical ignition timing faulty
Check ignition system
Insuffient fuel
Clean and check fuel system and carburettor
Engine takes air out of control
Check intake flange and carburettor if firmly setted
Insufficient cooling liquid
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Not enough air stream
Drive on briskly
Radiators very dirty
Clean radiators with water jet
Foam formation in cooling system
Replace cooling liquid, use anti freeze liquid with brand
name
Bent cooling hose
Shorten or replace cooling hose
Thermostat defective
Dismount and check thermostat (opening temperature 70°
C, 158° F) or replace it
Buckling gearing ventilation hose
Dislocate i.e. replace non-buckling vetilation hose
Engine oil level too high
Check engine oil level when the engine is warm; correct if necessary
Motor oil too thin (viscosity)
Use thicker engine oil; see chapter „Engine oil“
Capacitor
faulty
Remove right side cover and control connections. Check
capacitor and voltage regulator
Engine stops or splutters
in carburettor
Engine gets to hot,
High oil consumption
All switched
blown out
on
lamps
or
voltage
regulator
9-4D
TROUBLE SHOOTING – LC4 COMPETITION
TROUBLE
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Engine will not start
Engine will not idle
REMEDY
CAUSE
Operating error
Switch on ignition, switch on emergency OFF switch, open
fuel tap, tank fuel, do not use choke i.e. the hotstart device.
Pay attention to starting off information (see driving
instructions).
The motorcycle has been out of
operation for a longer period of
time. Therefore the float chamber
is filled with old fuel.
The easily inflammable components of the new fuels
evaporate during longer periods of standstill. When the
motorcycle has been out of operation for more than a week,
it is therefore recommended to drain the old fuel from the
float chamber. The engine will immediately start off when the
float chamber is filled with new fuel.
Fuel supply interrupted
Close fuel tap, loosen fuel hose at carburetor, lead into a
basin and open fuel tap,
– if fuel leaks out, clean carburetor
– if no fuel leaks out, check tank ventilation, i.e. clean fuel
tap
Flooded engine
Fully open the throttle when starting or replace the spark
plug, respectively.
Sooty or wet spark plug
Clean / dry or replace spark plug.
Electrode gap too large
Adjust spark plug electrode gap to 0,7 mm
Spark plug connector or spark plug
faulty
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate kickstarter, a strong
spark must be produced at the spark plug
– If no spark is created exchange the spark plug.
– If the new spark plug doesn’t produce a spark either,
disconnect the spark plug connector from the ignition
cable, hold it approx. 5 mm from ground and start.
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
If
connector
oxidates
generator to ignition coil
from
Remove fuel tank, clean connector and treat with contact
spray
Short circuit cable scored in wiring
harness, ignition lock, emergency
OFF switch faulty
Remove fuel tank, draw off blue/black cable from orange
cable of ignition coil and check spark.
– If a spark is produced, seek fault in short circuit current
Water in short emergency OFF
switch
Remove 2-pole connector located underneath the headlight
mask, treat emergency OFF switch with contact spray
Water in carburetor or jets blocked
Dismount and clean carburetor
Carburetor does not fit in properly
at intake flange
Check if carburetor is fitted in correctly
Idling jet blocked
Dismount carburetor and clean jets
Adjusting screws on carburetor
uncorrect adjusted
Adjust carburetor
Spark plug faulty
Exchange the spark plug
Ignition system faulty
Check ignition system
9-5D
REMEDY
CAUSE
TROUBLE
Carburetor fuel level too high
because
Dismount carburetor and check if worn out
Float needle is dirty or worn out
Replace float needle
Float leaks
Replace float
The cold starting system is
permanently activated due to a
lack of play in the choke cable.
Adjust choke cable.
Carburetor jets have loosened.
Retighten jets.
Defective electronic ignition timing
device.
Check ignition system
Fuel supply partically interrupted or
carburetor dirty
Clean and check fuel system as well as carburetor
Float is not tight
Replace the float
Air filter very dirty
Clean or replace air filter
Valve gap to small
Adjust valve gap
Loss of compression because hand
decompressor has no play
Check setting of the hand decompression cable
Electronical ignition timing faulty
Check ignition system
Insufficient cooling liquid
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Radiators very dirty
Clean radiators with water jet
Foam formation in cooling system
Replace cooling liquid, use anti freeze liquid with brand name
Bent cooling hose
Shorten or replace cooling hose
Thermostat defective
Dismount and check thermostat (opening temperature 70°C,
158°F) or replace it
Buckling gearing ventilation hose
Dislocate i.e. replace non-buckling ventilation hose
Engine oil level too high
Check engine oil level when the engine is warm; correct if
necessary
Motor oil too thin (viscosity)
Use thicker engine oil; see chapter „Engine oil“
All lamps that were on
have burned out.
Defective voltage regulator.
Remove seat, check connections, Check the voltage
regulator
Headlight
light fail.
parking
Blown fuse.
Replace fuse (below the headlight mask).
Flasher lights, brake light,
fan and horn fail.
Blown fuse
Replace fuse (below the headlight mask).
Engine does not rev high
Engine will not reach full
power
Engine gets to hot,
cooling liquid tmperature
warning lamp lights up
High oil consumption
and
9-6D
TROUBLE
The neutral indicator lamp
doesn’t light up when the
motorcycle is put into
neutral.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Discharged battery.
REMEDY
CAUSE
Defective indicator lamp.
Replace indicator lamp.
Defective idle switch.
Connect the cable to ground. The neutral switch must be
replaced if the indicator lamp lights up.
Loose connections, defective cable.
Check connections and cable.
The ignition (power consumer) has
been left on.
Recharge the battery according to the relevant instructions.
The generator doesn’t recharge the
battery.
Remove the seat and check the voltage regulator
connections. Check the voltage regulator and the generator.
9-7D
TROUBLE SHOOTING LC4
TROUBLE
CAUSE
REMEDY
Operating errror
Turn on the ignition, switch the gear to neutral and switch
the emergency OFF switch on.
Discharged battery.
Recharge the battery and investigate the causes for
discharging.
Defect ignition lock or emergency
OFF switch
Check ignition lock and emergency OFF switch.
The engine doesn't crank.
The neutral indicator
lamp doesn't light up.
Blown fuse safe-starting system.
Replace fuse (below the headlight mask).
Blown main fuse.
Remove seat and replace the main fuse.
The engine cranks only
with pulled clutch lever
Defect safe-starting system.
Check the components of the safe-starting system.
Engine cranks with gear
engaged.
Defect safe-starting system.
Check the components of the safe-starting system.
Engine cranks but doesn’t
start.
Operating error
Open fuel tap, tank fuel, you did not use choke i.e. the
warmstart device. Pay attention to starting off information
(see driving instructions).
The motorcycle has been out of
operation for a longer period of
time. Therefore old fuel has
accumulated in the float chamber
The easily inflammable components of the new fuels
evaporate during longer periods of standstill.
When the motorcycle has been out of operation for more
than a week, it is therefore recommended to drain the old
fuel from the float chamber. The engine will immediately start
off when the float chamber is filled with new fuel.
Fuel supply interrupted
Loosen fuel hose at carburettor, lead into a basin and open
fuel tap
– if fuel leaks out, the carburetor might need cleaning
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap
Flooded engine
Fully open the throttle when starting or exchange the spark
plug, respectively
Sooty or wet spark plug
Clean and dry the spark plug or exchange it, respectively
Electrode gap too large
Adjust spark plug electrode gap to 0,7 mm
Spark plug connector or spark plug
faulty
Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate starter, a strong spark
must be produced at the spark plug
– If no spark is created exchange the spark plug.
– If the new spark plug doesn't produce a spark either,
disconnect the spark plug connector from the ignition cable,
hold it a distance of approx. 5 mm from ground and start.
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
The plug connection of the CDIunit, the pulse generator or the
ignition coil has oxydized
Remove the seat, the right side cover and the fuel tank.
Clean the plug connection and treat it with contact spray
Water in carburetor or jets blocked
Dismount and clean carburetor
Engine doesn’t crank.
9-8D
Engine fails to idle
Engine does not rev high
Art.-Nr. 3.206.006 -E
Engine will not reach full
power
Repair manual KTM LC4
Engine overheats
High oil consumption
REMEDY
CAUSE
TROUBLE
Glogged idling jet
Disassemble carburetor and clean jets
Uncorrect adjustment of adjusting
screws on carburetor
Adjust carburetor
Defective spark plug
Replace spark plug
Defective ignition system
Check ignition system
Carburetor fuel level too high
because
Dismount carburetor and check if worn out
Float needle is dirty or worn out
Replace float needle
Float leaks
Replace float
The cold starting system is
permanently activated due to a
lack of play in the choke cable.
Adjust choke cable.
Defective membrane of slide (640)
Replace membrane
Loose carburettor jets
Tighten jets
Electronic ignition timing faulty
Check pulse generator and ignition system
Fuel supply partically interrupted or
carburetor dirty
Clean and check fuel system as well as carburetor
Float leaks
Replace the float
Defective membrane of slide (640)
Replace membrane
Air filter very dirty
Clean or replace air filter
Valve clearance to small
Adjust valve clearance
Loss of compression because hand
decompressor has no play
Check setting of the hand decompression cable
Electronic ignition timing faulty
Check pulse generator and ignition system
Insufficient cooling liquid
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Radiator fins are extremely dirty
Clean radiator with water jet
Foam forms in cooling system
Replace cooling liquid, use antifreezer with brand name
Bent cooling hose
Shorten or replace cooling hose
Thermostat defective
Remove and check thermostat (opening temperature 70°C
(158°F) or replace it.
Blown fan fuse
Replace fuse and check if fan operates properly (see below)
Defect thermo switch
Replace thermo switch
Fan defective
Check if fan operates properly. To do this, start the engine,
then bypass the connections to the thermo switch (bottom
right radiator).
Buckling gear ventilation hose
Readjust or replace ventilation hose
Engine oil level too high
Check engine oil level when the engine is warm; correct if
necessary
Engine oil too thin (viscosity)
Use thicker engine oil; see chapter „Engine oil“
9-9D
REMEDY
CAUSE
TROUBLE
All switched on lamps
blown out
Voltage regulator faulty
Remove seat and check connections. Check voltage regulator
Headlight
light fail
parking
Blown fuse
Replace fuse (below the headlight mask).
Flasher lights, brake light,
fan and horn fail
Blown fuse
Replace fuse (below the headlight mask).
The NEUTRAL lamp is
not on even though the
gear is in NEUTRAL
Defect indicator lamp.
Replace indicator lamp
Defect neutral switch.
Connect cable to ground; neutral switch must be replaced if
indicator lamp lights up.
Loose connections, defect cable.
Check connections and cables.
The ignition (power consumer)
hasn’t been switched off
Recharge the battery according to the relevant instructions.
The battery isn’t charged by the
generator
Remove seat and check voltage regulator connections; Check
voltage regulator and generator.
and
The battery is discharged
10-1D
TECHNICAL SPECIFICATIONS
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
INDEX
MODEL 1998
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
–
–
–
–
–
–
–
–
–
–
ENGINE 400/540 SXC . . . . . . . . . . . . . .10-3
CHASSIS 400/540 SXC . . . . . . . . . . . . . .10-5
ENGINE 400/620 SX, SC . . . . . . . . . . . . .10-6
CHASSIS 400/620 SX, SC . . . . . . . . . . . .10-8
ENGINE 620 LC4 COMPETITION . . . . . .10-9
CHASSIS 620 LC4 COMPETITION . . . . .10-11
ENGINE 400/540 SXC . . . . . . . . . . . . . .10-12
CHASSIS 400/640 LC4 . . . . . . . . . . . . .10-15
CHASSIS 640 ADVENTURE-R . . . . . . . .10-16
CHASSIS 640 DUKE-E . . . . . . . . . . . . . .10-17
MODEL 1999
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
–
–
–
–
–
–
–
–
–
–
–
–
ENGINE 400/540 SXC, 620 SX . . . . . . . 10-18
CHASSIS 400/540 SXC, 620 SX . . . . . . 10-20
ENGINE 400/620 SC . . . . . . . . . . . . . . 10-21
CHASSIS 400/620 SC . . . . . . . . . . . . . 10-23
ENGINE 620 LC4 COMPETITION . . . . . 10-24
CHASSIS 620 LC4 COMPETITION . . . . 10-26
ENGINE 400/640 LC4 . . . . . . . . . . . . . .10-27
CHASSIS 400/640 LC4 . . . . . . . . . . . . .10-29
ENGINE 640 ADVENTURE-R . . . . . . . . .10-30
CHASSIS 640 ADVENTURE-R . . . . . . . .10-32
ENGINE 640 DUKE . . . . . . . . . . . . . . . .10-33
CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-35
MODEL 2000
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
–
–
–
–
–
–
–
–
–
ENGINE SC, SUPERMOTO . . . . . . . . . . 10-36
CHASSIS SC, SUPERMOTO . . . . . . . . . 10-38
ENGINE LC4-E, ADVENTURE, DUKE . . .10-39
CHASSIS LC4-E SUPERMOTO . . . . . . . .10-41
CHASSIS 640 ADVENTURE-R . . . . . . . .10-42
CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-43
CHASSIS 640 DUKE AUS . . . . . . . . . . .10-44
ENGINE 400 SXC . . . . . . . . . . . . . . . . . 10-45
CHASSIS 400/540 SXC . . . . . . . . . . . . .10-46
10
10-2D
INDEX
Art.-Nr. 3.206.006 -E
MODEL 2001
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
–
–
–
–
–
–
–
ENGINE 620 SC, SUPERMOTO . . . . . . 10-47
CHASSIS 620 SC, SUPERMOTO . . . . . . 10-49
ENGINE LC4-E, ADVENTURE, DUKE . . .10-50
CHASSIS LC4-E, SUPERMOTO . . . . . . .10-52
CHASSIS 640 LC4 ADVENTURE . . . . . .10-53
CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-54
CHASSIS 640 DUKE USA, AUS . . . . . . .10-55
MODELL 2002
TECHNICAL SPECIFICATIONS – ENGINE 625 SC, SUPERMOTO . . .
TECHNICAL SPECIFICATIONS – CHASSIS 625 SC, SUPERMOTO . . .
TECHNICAL SPECIFICATIONS – ENGINE 640 LC4, ADVENTURE, DUKE
TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4, SUPERMOTO . .
TECHNICAL SPECIFICATIONS – CHASSIS 640 ADVENTURE . . . . . .
TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . .
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10-56
10-57
10-58
10-59
10-60
10-61
MODELL 2003
TECHNICAL SPECIFICATIONS – ENGINE 625 SXC . . . . . . . . . . . . . .
TECHNICAL SPECIFICATIONS – CHASSIS 625 SXC . . . . . . . . . . . . .
TECHNICAL SPECIFICATIONS – ENGINE 640 LC4, ADVENTURE, DUKE
TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4, SUPERMOTO . .
TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4 ADVENTURE . . .
TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . .
TECHNICAL SPECIFICATIONS – ENGINE 660 SMC . . . . . . . . . . . . .
TECHNICAL SPECIFICATIONS – CHASSIS 660 SMC . . . . . . . . . . . .
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10-62
10-63
10-64
10-65
10-66
10-67
10-68
10-69
Repair manual KTM LC4
TIGHTENING TORQUES
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-71
ASSEMBLY CLEARANCE, WEAR LIMIT . . . . . . . . . . . . . . . . . . . . . . . . .10-72
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
Ignition system
Ignition timing
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Art.-Nr. 3.206.006 -E
400 LC4
540 LC4
Liquid-cooled single cylinder 4-stroke engine with and without balancer shaft
398 cm3
538,5 cm3
89 / 64 mm
95 / 76 mm
10,8 : 1
11,1 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249° (249/1)
IO 22° BTDC
EO 60° BBDC
IO 13° BTDC
EO 53° BBDC
IC 42° ABDC
EC 4° ATDC
IC 51° ABDC
EC 11° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,20 mm Exhaust: 0,20 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through two Eaton-Oilpumps with oil sump
see bellow #
1,40liters
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
contactless thyristor ignition with electronic advanced system type SEM
400 SXC : adjustment to max. 38 ° BTDC at 6000 rpm
540 SXC: adjustment to max. 32 ° BTDC at 6000 rpm
12V 130W
NGK D8EA
0,6 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
TECHNICAL SPECIFICATIONS – ENGINE
Repair manual KTM LC4
axial play.......................................0,03 - 0,12 mm (0,001-0,005 in)
run out of crank stud ......................max. 0,04 mm
(0,0016 in)
Connecting rod bearing radial play .......................................max. 0,05 mm
(0,0019 in)
axial play.........................................max. 1,00 mm
(0,04 in)
Piston
assembly clearance 400/540/620 ...max. 0,12 mm
(0,005 in)
Piston rings end gap compression rings............................max. 0,60 mm
(0,023 in)
oil scraper ring ................................max. 0,80 mm
(0,031 in)
Valves
seat sealing intake...........................max. 1,50 mm
0,059 in)
seat sealing exhaust ........................max. 2,00 mm
(0,079 in)
run out of valve heads ....................max. 0,03 mm
(0,001 in)
valve guides diameter .....................max. 7,05 mm
(0,277 in)
Oil pump
clearance outer rotor - housing .......max. 0,20 mm
(0,008 in)
clearance outer rotor - inner rotor...max. 0,20 mm
(0,008 in)
Bypaß valve
minimum spring lenght ...............................25 mm
(1 in)
Clutch discs
wear limit organic ......................................2,5 mm
(0,1 in)
Transmission shafts axial play...........................................0,1 - 0,4 mm
(0,004 in)
Clutch
minimum clutchspring lenght .........34,5 mm (new 37 mm)(1,36 in - new 1,45 in)
Crank shaft
TOLERANCE, ASSEMBLY CLEARANCE
400/540 SXC ‘98
10-3D
M18x1,5
M12x1,5
Hexagon nut for inner clutch hub
Kickstarter stop bolt
60 Nm (44 ft.lb)
20 Nm (15 ft.lb)
M6x50/M6x55 (12.9)
M6x65/M6x70 (8.8)
M10
M10
M10
M22x1,5
M12x1,5
M12x1,5
M8x1
M10x1
M8x1
M12x1,5
M7x0,75
M12
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
Cylinder head bolts
Collar nuts at cylinder base
Hexagon bolt chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Banjo bolts oil lines
Banjo bolt oil lines
Jet screw clutch cover
Bolt plug timing-chain tensioner
Counternuts valve adjusting screws
Spark Plug
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
(6 ft.lb)
(6 ft.lb)
(7 ft.lb)
(7 ft.lb)
400 SXC (20 kW)
PHM 38 ND
120198
140
AB 265
50
K 32
II
1,5 turn
50/1
45
slide stop 56mm
PHM 38 ND
120198
140
AB 265
50
K 32
II
1,5 turn
50/1
45
–
540 SXC
VHSB 38 QS
081297
185
FN 260
33
K 32
II
1,5 turn
50
40
–
20 Nm (15 ft.lb)
10 Nm
15 Nm (11 ft.lb)
10 Nm
20 Nm (15 ft.lb)
20 Nm (15 ft.lb)
30 Nm (22 ft.lb)
Loctite 243 + 40 Nm (30 ft.lb)
40 Nm (30 ft.lb)
50 Nm (37 ft.lb)
8 Nm
20 Nm (15 ft.lb)
8 Nm
400 SXC
BASIC CARBURETOR SETTING
20 Nm (15 ft.lb)
M6x25
(6 ft.lb)
AH bolt cylinder head top sect.
Loctite 243 + 8 Nm
Hexagon bolt camshaft gear
Loctite 243 + 35 Nm (26 ft.lb)
M6
M10
AH bolts oil pump
50 Nm (37 ft.lb)
Loctite 243 + 80 Nm (59 ft.lb)
M12x1 LH thread
Collar nut flywheel
Loctite 243 + 170 Nm (125 ft.lb)
M20x1,5
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
10W 40
10W 50
10W 60
–
15W 40
15W 50
15W 60
+
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
POOR
!
Use only oil brands, which meet quality requirements
of API-classes SF, SG or SH (informations on bottles)
or higher. Both, mineral and synthetic oils with above
specifications can be used.
32°F
0°C
TEMPERATURE
API: SF, SG, SH
Engine oil
VHSB 38 QS
091297
140 (185)
FN 260
33
K 32
II
1,5 turn
50
40
slide stop 36mm
540 SXC (20 kW)
#
10-4D
540:15:50
540: 122 kg (269 lbs)
350 mm (13,8 in)
Ground clearance
400: 121 kg (267 lbs)
940 mm (37 in)
Seat high
Dead weight without fuel
1510 ± 10 mm (59,4 ± 0,4 in)
62,5°
/8 x 1/4" O-Ring
5
400: 14:50
Wheel base
Steering angle
Chain
Final drive ratio
9 liter (3 US gallons)
of that 1,5 liter (0,4 US gallons) reserve
140/80 - 18
1,2 bar (17 psi)
2,0 bar (28 psi)
–
Tyres rear
Air pressure offroad
Air press. road, driver only
Air press. road with passenger
Fuel tank capacity
90/90 - 21
1,0 bar (14 psi)
1,5 bar (21 psi)
–
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
brake disc Ø = 260 mm (10,2 in)
Disc brake with carbon-steel brake disc , brake caliper floated
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Tyres front
Air pressure offroad
Air press. road, driver only
Air press. road with passenger
Rear brake
Front brake
Rear suspension
285/320 mm (11,2/12,6 in)
WP Extreme
Fork
400/540 SXC
Central chrome-moly-steel frame
Frame
Wheel travel front/rear
Art.-Nr. 3.206.006 -E
SAE 5
ca 800 ccm
155 mm
7 mm
4,2 N/mm
12
12
WP 09.18.S7.44
M 10
M8
M 20x1,5
M 14x1,5
M8
M8
M8
M6
M8
M 10
Collar bolt front axle
Brake caliper front
Collar nut rear axle
Hex. nut swing arm bolt
Clamping bolt top triple clamp
Clamping bolt bottom triple clamp
Clamping bolts fork leg axle passage
Other bolts chassis
TORQUES
40 Nm
10 Nm
25 Nm
45 Nm
10 Nm
20 Nm
15 Nm
100 Nm
80 Nm
Loctite 243 + 25 Nm
23 mm
Spring preload
4
63/260
Rebound adjuster
Spring
3
Compression adjuster
WP 01.18.Q7.82
(7,4 ft.lb)
(18 ft.lb)
(33 ft.lb)
(7,4 ft.lb)
(15 ft.lb)
(11 ft.lb)
(74 ft.lb)
(59 ft.lb)
(18 ft.lb)
(30 ft.lb)
STANDARD-ADJUSTMENT - SHOCK ABSORBER
NOTE FOR WHITE POWER FORKS:
The damping units in the left and the right fork leg are of different design. Make
sure not to mix them up in case of repair or service works.
Fork oil
Capacity per fork leg
Air chamber length
Spring preload
Spring
Rebound adjuster
Compression adjuster
STANDARD ADJUSTMENT - FORK
TECHNICAL SPECIFICATIONS - CHASSIS 400/540 SXC ‘98
Repair manual KTM LC4
10-5D
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
Ignition system
Ignition timing
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
400 LC4
620 LC4
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
398 cm3
609 cm3
89 / 64 mm
101 / 76 mm
10,8 : 1
SX: 11,5 : 1
SC: 10,4 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249° (249)
IO 22° BTDC
EO 59° BBDC
IO 14° BTDC
EO 56° BBDC
IC 47° ABDC
EC 10° ATDC
IC 55° ABDC
EC 13° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,20 mm Exhaust: 0,20 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through Eaton-Oilpump with oil sump
see bellow #
1,40 liters
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
contactless thyristor ignition with electronic advanced system type SEM
adjustment to max. 38 ° BTDC at 6000 rpm
SX: adjustment to max. 38 ° BTDC at 6000 rpm
SC: adjustment to max. 32 ° BTDC at 6000 rpm
12V 130W
NGK D8EA
0,6 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
TECHNICAL SPECIFICATIONS – ENGINE
Hexagon nut at primary gear
Collar nut flywheel
Hexagon nut for inner clutch hub
Kickstarter stop bolt
AH bolts oil pump
Hexagon bolt camshaft gear
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
Cylinder head bolts
Collar nuts at cylinder base
Hexagon bolt chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Banjo bolts oil lines
Banjo bolt oil lines
Jet screw clutch cover
Bolt plug timing-chain tensioner
Counternuts valve adjusting screws
Spark plug
M20x1,5
Loctite 243 + 170Nm
M12x1 LH thread
60 Nm
M18x1,5
Loctite 648 + 80 Nm
M12x1,5
70 Nm
M6
Loctite 243 + 8 Nm
M10
35 Nm
M6x25
8 Nm
M6x50/M6x55 (12.9)
20 Nm
M6x65/M6x70 (8.8)
8 Nm
M10
50 Nm
M10
40 Nm
M10
Loctite 243 + 40 Nm
M22x1,5
30 Nm
M12x1,5
20 Nm
M12x1,5
20 Nm
M8x1
10 Nm
M10x1
15 Nm
M8x1
10 Nm
M12x1,5
20 Nm
M7x0,75
20 Nm
M12
20 Nm
TIGHTENING TORQUES - ENGINE
(125
(44
(59
(52
(6
(26
(6
(15
(6
(37
(30
(30
(22
(15
(15
(7
(11
(7
(15
(15
(15
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
Piston
assembly clearance 400/620 ...........max. 0,12 mm
(0,005 in)
Piston rings end gap compression rings............................max. 0,60 mm
(0,023 in)
oil scraper ring ................................max. 0,80 mm
(0,031 in)
Valves
seat sealing intake...........................max. 1,50 mm
0,059 in)
seat sealing exhaust ........................max. 2,00 mm
(0,079 in)
run out of valve heads ....................max. 0,03 mm
(0,001 in)
valve guides diameter .....................max. 7,05 mm
(0,277 in)
Oil pump
clearance outer rotor - housing .......max. 0,20 mm
(0,008 in)
clearance outer rotor - inner rotor...max. 0,20 mm
(0,008 in)
Bypaß valve
minimum spring lenght ...............................25 mm
(1 in)
Clutch discs
wear limit organic ......................................2,5 mm
(0,1 in)
Transmission shafts axial play...........................................0,1 - 0,4 mm
(0,004 in)
Clutch
minimum clutchspring lenght .........34,5 mm (new 37 mm)(1,36 in - new 1,45 in)
axial play.......................................0,03 - 0,12 mm (0,001-0,005 in)
run out of crank stud ......................max. 0,04 mm
(0,0016 in)
Connecting rod bearing radial play .......................................max. 0,05 mm
(0,0019 in)
axial play.........................................max. 1,00 mm
(0,04 in)
Crank shaft
TOLERANCE, ASSEMBLY CLEARANCE
400/620 SX, SC ‘98
10-6D
#
–
15W 40
15W 50
15W 60
+
!
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
POOR
Use only oil brands, which meet quality requirements
of API-classes SF, SG or SH (informations on bottles)
or higher. Both, mineral and synthetic oils with above
specifications can be used.
32°F
0°C
TEMPERATURE
10W 40
10W 50
10W 60
Engine oil
PHM 38 SD
4894/6
190
DR 270
45
K 51
2 nd
1,5 turn
40
45
–
PHM 38 SD
300896
150
DR 266
45
K 51
3 rd
1,5 turn
40
45
slide stop 22 mm
API: SF, SG, SH
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
400 SC
400 SC (20 kW)
BASIC CARBURETOR SETTING
Repair manual KTM LC4
PHM 40 SD
4922
195
DR 272
45
K 51
2 nd
1,5 turn
40
45
–
620 SX
620 SC
PHM 40 SD
110996
155
DR 268
45
K 51
3 rd
1,5 turn
40
45
slide stop 26 mm
620 SC (20 kW)
Art.-Nr. 3.206.006 -E
10-7D
62,5°
Steering angle
350 mm (13,8 in)
Ground clearance
211 kg (466 lbs)
335 kg (737 lbs)
350 kg (770 lbs)
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
400 : 121 kg (267 lbs)
620 : 122 kg (269 lbs)
940 mm (37 in)
Seat high
Dead weight without fuel
1510 ± 10 mm (59,4 ± 0,4 in)
Wheel base
115 kg (254 lbs)
/8 x 1/4"
5
14:48, 14:50, 15:40, 15:45, 15:48 15:50, 16:40, 16:45
Chain
Final drive ratio
140/80-18 70R
1,2 bar (17 psi)
2,0 bar (28 psi)
90/90-21
1,0 bar (14 psi)
1,5 bar (21 psi)
9 liter (3 US gallons)
of that 1,5 liter (0,4 US gallons) reserve
110/90-19
1,2 bar (17 psi)
–
Tyres rear
Air pressure offroad
Air press. road, driver only
Fuel tank capacity
80/100-21
1,0 bar (14 psi)
–
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Rear brake
Tyres front
Air pressure offroad
Air press. road, driver only
Disc brake with carbon-steel brake disc , brake caliper floated
brake disc Ø = 260 mm (10,2 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
400/620 SC
Front brake
Rear suspension
285/320 mm (11,2/12,6 in)
WP Extreme
Fork
Wheel travel front/rear
Central chrome-moly-steel frame
Frame
620 SX
8
SAE 5
SAE 5
ca 800 ccm
155 mm
7 mm
4,2 N/mm
12
12
WP 09.18.S7.44
M 20x1,5
M 14x1,5
M 8 (Extreme)
M8 (USD)
M 8 (Extreme)
M8 (USD)
M 7/M8
M6
M8
M10
Hex. nut swing arm bolt
Clamping bolt top triple clamp
Clamping bolt bottom triple clamp
Clamping bolts fork leg axle passage
Other bolts chassis
M8
Brake caliper front
15 Nm
15 Nm
100 Nm
80 Nm
20 Nm
15 Nm
(19 ft.lb)
(30 ft.lb)
10 Nm
25 Nm
45 Nm
(7 ft.lb)
(19 ft.lb)
(33 ft.lb)
(5/7 ft.lb)
(15 ft.lb)
(11 ft.lb)
(11 ft.lb)
(11 ft.lb)
(74 ft.lb)
(59 ft.lb)
+ Loctite 243
25 Nm
40 Nm
7/10 Nm
23 mm
66/260
4
3
WP 01.18.Q7.81
Collar nut rear axle
M 10
23 mm
63/260
4
3
Collar bolt front axle
TORQUES
Spring preload
Spring
Rebound adjuster
Compression adjuster
WP 01.18.Q7.82
STANDART-ADJUSTMENT - SHOCK ABSORBER
NOTE FOR WHITE POWER FORKS:
The damping units in the left and the right fork leg are of different design. Make
sure not to mix them up in case of repair or service works.
Fork oil
140 mm
ca 800 ccm
Capacity per fork leg
8 mm
4,4 N/mm
12
Air chamber length
Spring preload
Spring
Rebound adjuster
Compression adjuster
WP 09.18.S7.40
STANDARD ADJUSTMENT - FORK
TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SX, SC ‘98
10-8D
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Art.-Nr. 3.206.006 -E
620 LC4 COMP.
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
609 cm3
101 / 76 mm
10,4 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249° (249/1)
IO 15° BTDC
EO 52° BBDC
IC 54° ABDC
EC 17° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through Eaton-Oilpump with oil sump
see bellow #
2,1 liters including frame
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
contactless thyristor ignition with electronic advanced system type SEM
adjustment to max. 32 ° BTDC at 6000 rpm
12V 130W
NGK DR8EA
0,7 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
TECHNICAL SPECIFICATIONS – ENGINE
Repair manual KTM LC4
Piston
assembly clearance .........................max. 0,12 mm
(0,005 in)
Piston rings end gap compression rings............................max. 0,60 mm
(0,023 in)
oil scraper ring ................................max. 0,80 mm
(0,031 in)
Valves
seat sealing intake...........................max. 1,50 mm
0,059 in)
seat sealing exhaust ........................max. 2,00 mm
(0,079 in)
run out of valve heads ....................max. 0,05 mm
(0,002 in)
valve guides diameter .....................max. 7,05 mm
(0,277 in)
Oil pump
clearance outer rotor - housing .......max. 0,20 mm
(0,008 in)
clearance outer rotor - inner rotor...max. 0,20 mm
(0,008 in)
Bypaß valve
minimum spring lenght ...............................25 mm
(1 in)
Clutch discs
wear limit organic ......................................2,5 mm
(0,1 in)
Transmission shafts axial play...........................................0,1 - 0,4 mm
(0,004 in)
Clutch
minimum clutchspring lenght .........34,5 mm (new 37 mm)(1,36 in - new 1,45 in)
axial play.......................................0,03 - 0,12 mm (0,001-0,005 in)
run out of crank stud ......................max. 0,08 mm
(0,0031 in)
Connecting rod bearing radial play .......................................max. 0,05 mm
(0,0019 in)
axial play.........................................max. 1,00 mm
(0,04 in)
Crank shaft
ASSEMBLY CLEARANCE, WEAR LIMIT
620 LC4 COMPETITION ‘98
10-9D
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
PHM 40 SD
110996
155
DR 268
45
K 51
3 rd
1,5 turn
40
45
slide stop 26 mm
620 LC4 COMP.
BASIC CARBURETOR SETTING
M6x50/M6x55 (12.9)
20 Nm (15 ft.lb)
M6x65/M6x70 (8.8)
8 Nm
(6 ft.lb)
M10
50 Nm (37 ft.lb)
M10
40 Nm (30 ft.lb)
M10
Loctite 243 + 40 Nm (30 ft.lb)
M22x1,5
30 Nm (22 ft.lb)
M12x1,5
20 Nm (15 ft.lb)
M12x1,5
20 Nm (15 ft.lb)
M8x1
10 Nm
(7 ft.lb)
M10x1
15 Nm (11 ft.lb)
M8x1
10 Nm
(7 ft.lb)
M12x1,5
20 Nm (15 ft.lb)
M7x0,75
20 Nm (15 ft.lb)
M 12
20 Nm (15 ft.Ib)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
Cylinder head bolts
Collar nuts at cylinder base
Hexagon bolt chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Banjo bolts oil lines
Banjo bolt oil lines
Jet screw clutch cover
Bolt plug timing-chain tensioner
Counternuts valve adjusting screws
Spark plug
(125
(44
(59
(37
(6
(26
(6
M20x1,5
Loctite 243 +170Nm
M12x1 LH thread
60 Nm
M18x1,5
Loctite 243 + 80 Nm
M12x1,5
50 Nm
M6
Loctite 243 + 8 Nm
M10
Loctite 243 + 35 Nm
M6x25
8 Nm
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
Collar nut flywheel
Hexagon nut for inner clutch hub
Kickstarter stop bolt
AH bolts oil pump
Hexagon bolt camshaft gear
AH bolt cylinder head top sect.
#
–
10W 40
10W 50
10W 60
0°C
32°F
15W 40
15W 50
15W 60
+
!
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
POOR
Use only oil brands, which meet quality requirements
of API-classes SF, SG or SH (informations on bottles)
or higher. Both, mineral and synthetic oils with above
specifications can be used.
Engine oil
TEMPERATURE
API: SF, SG, SH
10-10D
10-11D
TECHNICAL SPECIFICATIONS - CHASSIS
620 LC4 COMP. ‘98
620 LC4 COMP.
Frame
Central chrome-moly-steel frame
Fork
WP Extreme
Wheel travel front/rear
Rear suspension
280 / 320 mm (11,0 / 12,6 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc , brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
brake disc Ø = 300 mm (11,8 in)
Tyres front
Air press. road, driver only
Air press. road with passenger
90/90-21 T63
1,5 bar (21 psi)
2,0 bar (28 psi)
Tyres rear
Air press. road, driver only
Air press. road with passenger
130/80-18 T63
2,0 bar (28 psi)
2,2 bar (31 psi)
Fuel tank capacity
12 liter (3,2 US gallons)
of that 2,5 liter (0,7 US gallons) res
Final drive ratio
16:40
Chain
O-ring 5/8 x 1/4"
Battery
maintenance-free battery 12V 8Ah
Steering angle
62,5°
1510 ± 10 mm (59,4 ± 0,4 in)
Art.-Nr. 3.206.006 -E
Wheel base
Seat high
955 mm (37,6 in)
Ground clearance
335 mm (13,2 in)
Dead weight without fuel
133 kg (293 lbs)
Max. permissible front axle load
211 kg (466 lbs)
Max. permissible rear axle load
335 kg (737 lbs)
Max. permissible laden weight
350 kg (770 lbs)
STANDARD-ADJUSTMENT - SHOCK ABSORBER
STANDARD ADJUSTMENT - FORK
118 S 701
918 S 757
Compression adjuster
3
Compression adjuster
12
Rebound adjuster
5
Rebound adjuster
12
Spring
66/260
Spring
Spring preload
23 mm
Spring preload
10 mm
Air chamber length
160 mm
Capacity per fork leg
Fork oil
Repair manual KTM LC4
NOTE FOR WP EXTREME FORKS:
The damping units in the left and the right fork leg
are of different design. Make sure not to mix them
up in case of repair or service works.
TORQUES
Collar bolt front axle
M 10
40 Nm
(30 ft.lb)
Brake caliper front
M8
25 Nm
(19 ft.lb)
+ Loctite 243
Collar nut rear axle
M 20x1,5
80 Nm
(59 ft.lb)
Hex. nut swing arm bolt
M 14x1,5
100 Nm
(74 ft.lb)
Clamping bolt top triple clamp
M8
15 Nm
(11 ft.lb)
Clamping bolt bottom triple clamp
M8
20 Nm
(15 ft.lb)
Clamping bolts fork leg axle passage
M8
10 Nm
(7 ft.lb)
Other bolts chassis
M6
M8
M10
10 Nm
25 Nm
45 Nm
(7 ft.lb)
(19 ft.lb)
(33 ft.lb)
4,4 N/mm
ca. 800 ccm
SAE 5
10-12D
TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘98
Engine
Design
400 LC4
640 LC4
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
Displacement
398 ccm
624.6 ccm
Bore / Stroke
89 / 64 mm
101 / 78 mm
10,8 : 1
11 : 1
Ratio
Fuel
Valve timing
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
Camshaft
Valve timing by 1 mm
valve clearence
249° (249/1)
IO 22° BTDC
IC 47° ABDC
EO 60° BBDC
EC 4° ATDC
Valve diameter
Valve clearence cold
Intake: 36 mm
Intake: 0,20 mm
EO 53° BBDC
IC 51° ABDC
EC 11° ATDC
Exhaust: 30 mm
Exhaust: 0,20 mm
Crank shaft bearing
IO 13° BTDC
0,15 mm
Exhaust: 0,15 mm
2 cylinder roller bearing
Connecting rod bearing
needle bearing
Top end bearing
bronze bushing
Piston
forged/cast aluminium alloy
Piston rings
1 compression ring, 1 taper face ring, 1 oil scraper ring
Engine lubrication
two Eaten-oilpumps
Engine oil
see bellow #
Engine oil quantity
appr. 2,1 liters including frame
Primary ratio
straight geared spur wheels 30 : 81 teeth
Clutch
multi disc clutch in oil bath
Transmission
5-speed claw shifted
Ignition system
contactless DC-CDI ignition with digital advanced system type KOKUSAN
Ignition timing
adjustment to max. 38° BTDC at 6000 rpm
Generator
12V 200W
Spark plug
NGK DR8EA
Spark plug gap
0,7 mm
Cooling system
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
Cooling liquid
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
Starting equipment
electric starter and kickstarter
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
axial play.............................................................................................0,03 - 0,12 mm
(0,001-0,005 in)
run out of crank stud ............................................................................max. 0,08 mm
(0,0031 in)
Connecting rod bearing
radial play .............................................................................................max. 0,05 mm
(0,0019 in)
axial play...............................................................................................max. 1,00 mm
(0,04 in)
Piston
assembly clearance ..............................................................................max. 0,12 mm
(0,005 in)
Piston rings end gap
compression rings .................................................................................max. 0,60 mm
(0,023 in)
oil scraper ring ......................................................................................max. 0,80 mm
(0,031 in)
seat sealing intake.................................................................................max. 1,50 mm
0,059 in)
seat sealing exhaust ..............................................................................max. 2,00 mm
(0,079 in)
run out of valve heads ..........................................................................max. 0,05 mm
(0,002 in)
valve guides diameter ...........................................................................max. 7,05 mm
(0,277 in)
clearance outer rotor - housing .............................................................max. 0,20 mm
(0,008 in)
clearance outer rotor - inner rotor.........................................................max. 0,20 mm
(0,008 in)
Bypaß valve
minimum spring lenght.....................................................................................25 mm
(1 in)
Clutch discs
wear limit organic ............................................................................................2,5 mm
(0,1 in)
Transmission shafts
axial play.................................................................................................0,1 - 0,4 mm
(0,004 in)
Clutch
minimum clutch spring lenght .................................................34,5 mm (new 37 mm)(1,36 in - new 1,45 in)
Valves
Oil pump
10-13D
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
M20x1,5
Hexagon nut flywheel
M16x1,25 LH thread
Loctite 243 + 170Nm (125 ft.lb)
Hexagon nut for inner clutch hub
M18x1,5
Kickstarter stop bolt
M12x1,5
Allen head bolts oil pump
M6
Hexagon bolt camshaft gear
M10
Loctite 243 + 35 Nm (26 ft.lb)
Allen head bolts outer race
M6x12/M6x12,5
Loctite 648 + 18 Nm (13 ft.lb)
Allen head bolt cylinder head top sect.
M6x50/M6x55 (12.9)
Allen head bolt cylinder head top sect.
M6x25/M6x65/M6x70 (8.8)
Cylinder head bolts
M10
Collar nuts at cylinder base
M10
40 Nm (30 ft.lb)
Hexagon bolt chain sprocket
M10
Loctite 243 + 40 Nm (30 ft.lb)
Oil drain plug
M22x1,5
30 Nm (22 ft.lb)
Magnetic plug
M12x1,5
20 Nm (15 ft.lb)
Plug bypass valve
M12x1,5
20 Nm (15 ft.lb)
Crankshaft locating bolt
M8
25 Nm (18 ft.lb)
Hollow bolts oil lines
M8x1
10 Nm (7 ft.lb)
Hollow bolts oil lines
M10x1
15 Nm (11 ft.lb)
Jet screw clutch cover
M8
Bolt plug timing-chain tensioner
M12x1,5
150 Nm (110 ft.lb)
80 Nm (59 ft.lb)
50 Nm (37 ft.lb)
Loctite 243 + 8 Nm (6 ft.lb)
20 Nm (15 ft.lb)
8 Nm (6 ft.lb)
50 Nm (37 ft.lb)
10 Nm (7 ft.lb)
20 Nm (15 ft.lb)
Counternuts valve adjusting screws
M7x0,75
20 Nm (15 ft.lb)
Engine fastening bolt
M8
40 Nm (30 ft.lb)
M10
70 Nm (52 ft.lb)
Art.-Nr. 3.206.006 -E
GEAR RATIOS
Primary
ratio
Transmission
1st gear
2nd gear
3rd gear
4th gear
5th gear
30:81
14:35
15:24
18:21
20:19
22:18
Original final
drive ratio
Available chain
drive sprockets
Available final
drive sprockets
15:45
16:40
16:42
17:38
15
for chain
16 5
/8 x 1/4"
17
38
40
42
45
48
Engine oil
Repair manual KTM LC4
API: SF, SG, SH
TEMPERATURE
–
10W 40
10W 50
10W 60
0°C
32°F
+
15W 40
15W 50
15W 60
for chain
5
/8 x 1/4"
Use only oil brands (Shell Advance Ultra 4), which
meet quality requirements of API-classes SF, SG or SH
(informations on bottles) or higher. Both, mineral and
synthetic oils with above specifications can be used.
!
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
10-14D
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
400 LC4
25 kW
400 LC4
31 kW
PHM 38 ND
100197
130
AR 264
50
K 23
2 nd
1,5 turn
50/1
45 (50, 55)
slide stop 51 mm
PHM 38 ND
100197
130
AR 264
50
K 23
2 nd
1,5 turn
50/1
45 (50, 55)
–
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
640 DUKE-E
640 ADV.-R
640 DUKE-E
640 ADV.-R
25 kW
37 kW
PHM 40 SD
210198
155
DR 268
45
K 51
4. from top
1.5 turns
40
55
slide stop 28mm
PHM 40 SD
210198
155
DR 268
45
K 51
4. from top
1,5 turns
40
55
–
640 LC4
640 LC4
25 kW
37 kW
BST40-225
080298
142,5
689 X-6
45
6G5
3 rd
–
–
–
slide stop 17 mm
BST40-225
080298
142,5
689 X-6
45
6G5
3 rd
–
–
–
–
10-15D
TECHNICAL SPECIFICATIONS - CHASSIS 400 / 640 LC4 ‘98
400/640 LC4 ‘98
Frame
Central chrome-moly-steel frame
Fork
WP Extreme
Wheel travel front/rear
Rear suspension
280 / 320 mm (11 / 12.6 in)
Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing
Front brake
Disc brake with carbon-steel brake disc 300 mm (11.8 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated
Tyres front
90/90 - 21 Enduro 3
Air press. road, driver only
1.5 bar (22 psi)
Air press. road with passenger
2.0 bar (29 psi)
Tyres rear
140/80 - 18 Enduro 3
Air press. road, driver only
2.0 bar (29 psi)
Air press. road with passenger
2.2 bar (31 psi)
Fuel tank capacity
12 liter (3.2 US gallons),
Final drive ratio
2.5 liter (0,6 US gallons) reserve
400 LC4 = 15:45t
640 LC4 = 16:42t
Chain
O – Ring 5/8 x 1/4"
Battery
maintenance-free battery 12V 8Ah
Steering angle
62,5 °
Art.-Nr. 3.206.006 -E
Wheel base
1510 ± 10 mm (59.4 ± 0.4 in)
Seat high
955 mm (37.6 in)
Ground clearance
355 mm (13.8 in)
Dead weight without fuel
136 kg (300 lbs)
Max. permissible front axle load
211 kg (465 lbs)
Max. permissible rear axle load
335 kg (740 lbs)
Max. permissible laden weight
350 kg (773 lbs)
STANDARD ADJUSTMENT - FORK
STANDARD-ADJUSTMENT - SHOCK ABSORBER
118S701
918S757
Compression adjuster
12
Compression adjuster
Rebound adjuster
12
Rebound adjuster
Spring
Spring preload
10 mm (0,4 in)
Air chamber length
160 mm (6,3 in)
Capacity per fork leg
Spring preload
ca 800 ccm
Fork oil
Repair manual KTM LC4
Spring
4,4 N/mm
SAE 5
TORQUES
Collar bolt front axle
M10
Brake caliper front
M8
40 Nm
(30 ft.lb)
Loctite 243 + 25 Nm
(20 ft.lb)
Collar nut rear axle
M20x1,5
80 Nm
(60 ft.lb)
Hex. nut swing arm bolt
M14x1,5
100 Nm
(74 ft.lb)
Clamping bolt upper fork bridge
M8
25 Nm
(11 ft.lb)
Clamping bolt lower fork bridge
M8
20 Nm
(15 ft.lb)
Clamping bolts fork stubs
M8
10 Nm
(7 ft.lb)
Other bolts chassis
M6
10 Nm
(7 ft.lb)
M8
25 Nm
(20 ft.lb)
M10
45 Nm
(33 ft.lb)
3
5
66/260
23 mm (0,9 in)
62,5 °
154kg (340 lbs)
150 kg (331 lbs)
230 kg (507 lbs)
380 kg (839 lbs)
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
Ground clearance
Dead weight without fuel
940 mm (37 in)
320 mm (12,6 in)
Seat high
1510 ± 10 mm (59,4 ± 0,4 in)
Wheel base
Steering angle
maintenance-free battery 12V 8Ah
Battery
1
O – Ring /8 x /4"
5
16:40 t
3,8 liter (1 US gallons) reserve
Chain
Final drive ratio
28 liter (7,4 US gallons),
2,2 bar (31 psi)
Fuel tank capacity
2,0 bar (29 psi)
Air press. road with passenger
140/80 - 18 70R Enduro 3
Air press. road, driver only
Tyres rear
2,0 bar (29 psi)
Air press. road with passenger
90/90 - 21 54S Enduro 3
Tyres front
1,5 bar (22 psi)
Disc brake with carbon-steel brake disc 220 mm (8,7 in), brake caliper floated
Air press. road, driver only
Disc brake with carbon-steel brake disc 300 mm (11,8 in), brake caliper floated
Rear brake
Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing
Front brake
Rear suspension
300 / 320 mm (11,8 / 12,6 in)
WP-Extreme Ø 50 mm
Fork
Wheel travel front/rear
Central chrome-moly-steel frame
Frame
640 ADVENTURE R
SAE5
ca 800 ccm
155 mm (5,9 in)
10 mm (0,4 in)
4,4 N/mm
12
14
09.18.S7.55
M 10
5
10 Nm
25 Nm
45 Nm
M8
M8
M6
M8
M10
Clamping bolt lower fork bridge
Clamping bolts fork stubs
Other bolts chassis
10 Nm
20 Nm
15 Nm
100 Nm
M 14x1,5
M8
Clamping bolt upper fork bridge
80 Nm
40 Nm
23 mm (0,9 in)
Hex. nut swing arm bolt
M 20x1,5
Collar nut rear axle
Collar bolt front axle
TORQUES
Spring preload
70/260
Rebound adjuster
Spring
3
Compression adjuster
01.18.R7.97
(33 ft.lb)
(19 ft.lb)
(7 ft.lb)
(7 ft.lb)
(15 ft.lb)
(11 ft.lb)
(74 ft.lb)
(59 ft.lb)
(30 ft.lb)
STANDARD-ADJUSTMENT - SHOCK ABSORBER
Fork oil
Capacity per fork leg
Air chamber length
Spring preload
Spring
Rebound adjuster
Compression adjuster
STANDARD ADJUSTMENT - FORK
TECHNICAL SPECIFICATIONS - CHASSIS 640 ADVENTURE R ‘98
10-16D
10-17D
TECHNICAL SPECIFICATIONS - CHASSIS
Type
640 DUKE
Frame
KTM 640 DUKE-E ‘98
last edition
Central chrome-moly-steel frame
Fork
type
wheel travel
standard adjustment compression
standard adjustment rebound
fork leg projection upper fork bridge
oil capacity per fork leg
air chamber lenght
Rear suspension
WP - 4054 Roma Top adjuster
140 mm (5,5 in)
driver only = 14, with passenger = 14
driver only = 14, with passenger = 14
10 mm (0,4 in)
appr. 740 ccm (45 cubic in) / SAE 5
100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . type
WP central shock absorber BAVP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rear wheel travel
170 mm (6.7 in)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . standard adjustment compression
driver only = 3,
with passenger = 5
driver only = 5,
with passenger = 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . standard adjustment rebound
............................................................
spring preload . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spring type
70 - 260
Front brake
Art.-Nr. 3.206.006 -E
Rear brake
Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
front: 120/70 R 17 58H
2.0 bar (29 psi)
2.2 bar (32 psi)
11,3 liter (3 US gallons), out of this 1,5 liter (0,42 US gallons) reserve
Final drive ratio
17 : 38
Chain
Lamps
Battery
o-ring 5/8 x 1/4"
low beam
high beam
parking light
speedometer, tachometer light
indicator lamp
stop and taillight
flasher
H1 12V 55W (socket P14,5s)
H1 12V 55W (socket P14,5s)
12V 4W (socket Ba9s)
12V 1,2W (socket W2x4,6d)
12V 1,2W (socket W2x4,6d)
12V 21/5W (socket BaY15d)
12V 10W (socket Ba15s)
Repair manual KTM LC4
62,5°
1460 ± 15 mm (57.5 ± 0.6 in)
Seat high
860 mm (33.9 in)
Ground clearance
250 mm (9.9 in)
TORQUES
Front axle
Rear axle
Hex. nut swing arm bolt
Clamping bolt upper fork bridge
Clamping bolt lower fork bridge
AH bolts front brake caliper
AH bolt rear brake caliper support
Collar nuts chain tension eccentrics
Clamping bolts fork stubs
Other bolts chassis
HS1 12V 35/35W (socket Px43t)
HS1 12V 35/55W (socket Px43t)
12V 4W (socket W2.1 9,5D)
12V 1,2W (socket W2x4.6d)
12V 1,2W (socket W2x4.6d)
12V 21/5W (socket BaY15d)
12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
Steering angle
Wheel base
rear: 160/60 R 17 69H
2.2 bar (32 psi)
2.4 bar (35 psi)
M 17
40 Nm (30 ft.lb)
M 20x1.5 80 Nm (59 ft.lb)
M 14x1.5 100 Nm (74 ft.lb)
M8
15 Nm (18 ft.lb)
M8
15 Nm (11 ft.lb)
M10
40 Nm (30 ft.lb)
M10
40 Nm (30 ft.lb)
M10
40 Nm (30 ft.lb)
M8
15 Nm (11 ft.lb)
M6
10 Nm (7 ft.lb)
M8
25 Nm (22 ft.lb)
M10
45 Nm (33 ft.lb)
10-18D
TECHNICAL SPECIFICATIONS – ENGINE
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearance
Valve diameter
Valve clearance cold
Crankshaft bearing
Conrod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
400 SXC
398 ccm
89 / 64 mm
10,8 : 1
400/540 SXC, 620 SX ‘99
540 SXC
Liquid-cooled single cylinder 4-stroke engine
538,5 ccm
620 SX
609 ccm
101 / 76 mm
11,5 : 1
11,3 : 1
unleaded premium gasoline with at least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
IO 22° BTDC
EO 60° BBDC
IO 13° BTDC
EO 53° BBDC
IC 42° ABDC
EC 4° ATDC
IC 51° ABDC
EC 11° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,20 mm Exhaust: 0,20 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through 2 Eaten-oilpumps
see bellow #
1,45 liters (0,38 US gallons)
straight geared spur wheels 30 : 81 teeth
Clutch
Transmission
Gear ratio
multi disc clutch in oil bath
5-speed claw shifted
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
contactless thyristor ignition with electronic advanced system type SEM
400 SXC/620 SX: adjustment to max. 38 ° BTDC at 6000 rpm
540 SXC: adjustment to max. 32 ° BTDC at 6000 rpm
12V 130W
NGK D8EA
NGK DPR8 EA-9
0,90 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
Pump jet
400 SXC
400 SC (20 kW)
540 SXC
540 SXC (20 kW)
620 SX
PHM 38 ND
120198
150 (155)
AB 265
52 (50)
K 11
I
1,5 turn
50/1
45
–
33 (38)
PHM 38 ND
120198
150 (155)
AB 265
52 (50)
K 11
I
1,5 turn
50/1
45
slide stop 48mm
33 (38)
VHSB 38 QS
081297
185
FN 260 (FN 258)
33
K 35 (K 32)
II
1,5 turn
50
40
–
–
VHSB 38 QS
091297
140 (185)
FN 260 (FN 258)
33
K 35 (K32)
II
1,5 turn
50
40
PHM 40 SD
4922
195
DR 272
45
K 51
II
1,5 turn
40
45
–
–
slide stop 36mm
–
10-19D
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Conrod bearing
Piston forged
Piston cast
Piston rings end gap
Valves
Oil pump
Bypaß valve
Clutch discs
Clutch springs
Transmission shafts
axial play..................................................0,03 - 0,12 mm
run out of crank stud .................................max. 0,08 mm
radial play ..................................................max. 0,05 mm
axial play ...................................................max. 1,00 mm
assembly clearance ...................................max. 0,12 mm
assembly clearance ...................................max. 0,05 mm
compression rings ......................................max. 0,60 mm
oil scraper ring ...........................................max. 0,80 mm
seat sealing intake......................................max. 1,50 mm
seat sealing exhaust ...................................max. 2,00 mm
run out of valve heads ...............................max. 0,03 mm
valve guides diameter ................................max. 7,05 mm
clearance outer rotor - housing..................max. 0,20 mm
clearance outer rotor - inner rotor..............max. 0,20 mm
minimum spring length..........................................25 mm
wear limit organic .................................................2,5 mm
minimum length ...........................34,5 mm (new 37 mm)
axial play......................................................0,1 - 0,4 mm
(0,001-0,005 in)
(0,003 in)
(0,002 in)
(0,04 in)
(0,005 in)
(0,002 in)
(0,023 in)
(0,031 in)
0,059 in)
(0,080 in)
(0,001 in)
(0,277 in)
(0,008 in)
(0,008 in)
(1 in)
(0,1 in)
(1,36 in - new 1,45 in)
(0,004 - 0,016 in)
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
Collar nut flywheel
Hexagon nut for inner clutch hub
Kickstarter stop bolt
AH bolts oil pump
Hexagon bolt camshaft gear
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
Cylinder head bolts
Collar nuts at cylinder base
Hexagon bolt chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Banjo bolts oil lines
Banjo bolt oil lines
Jet screw clutch cover
Bolt plug timing-chain tensioner
Counternuts valve adjusting screws
Spark plug
Crankshaft locking bolt
Engine fastening bolt
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
20x1,5
12x1 LH thread
18x1,5
12x1,5
6
10
6x25
6x50/M 6x55 (12.9)
6x65/M 6x70 (8.8)
10
10
10
22x1,5
12x1,5
12x1,5
8x1
10x1
8x1
12x1,5
7x0,75
12x1,25
8
8
10
–
0°C
32°F
+
15W 40
15W 50
15W 60
(125 ft.lb)
(44 ft.lb)
(59 ft.lb)
(37 ft.lb)
(6 ft.lb)
(26 ft.lb)
(6 ft.lb)
(15 ft.lb)
(6 ft.lb)
(37 ft.lb)
(30 ft.lb)
(30 ft.lb)
(22 ft.lb)
(15 ft.lb)
(15 ft.lb)
(7 ft.lb)
(11 ft.lb)
(7 ft.lb)
(15 ft.lb)
(15 ft.lb)
(15 ft.Ib)
18 ft.lb)
(30 ft.lb)
(51 ft.lb)
Engine oil
Use only oil brands, (Shell Advance Ultra 4) which meet
quality requirements of API-classes SF, SG or SH
(informations on bottles) or higher. Both, mineral and
synthetic oils with above specifications can be used.
!
10W 40
10W 50
10W 60
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
#
API: SF, SG, SH
TEMPERATUR
Loctite 243 +170
60
Loctite 648 + 80
50
Loctite 243 + 8
Loctite 243 + 35
8
20
8
50
40
Loctite 243 + 40
30
20
20
10
15
10
20
20
20
25
40
70
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR.
10-20D
TECHNICAL SPECIFICATIONS - CHASSIS 400/540 SXC, 620 SX ‘99
400/540 SXC
Frame
620 SX
Central chrome-moly-steel frame
Fork
WP Extreme
Wheel travel front/rear
280/320 mm (11/12,6 in)
Rear suspension
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc Ø 260 mm (10,2 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21 54R
80/100-21 51M
Air pressure offroad
1,0 bar (14 psi)
1,0 bar (14 psi)
Air press. road, driver only
–
1,5 bar (21 psi)
Tyres rear
140/80-18 70R
110/90-19 62M
Air pressure offroad
1,2 bar (17 psi)
1,2 bar (17 psi)
Air press. road, driver only
2,0 bar (28 psi)
–
Fuel tank capacity
9 liter (3 US gallons) of that 1,5 liter (0,4 US gallons) reserve
Final drive ratio
400 = 14 : 50,
540 = 15 : 50
15 : 50
Chain
5/8 x 1/4 "
Steering angle
62,5°
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
940 mm (37 in)
Ground clearance
375 mm (14,8 in)
Dead weight without fuel
121 kg (267 lbs)
STANDARD ADJUSTMENT - FORK
STANDARD ADJUSTMENT - SHOCK ABSORBER
09.18.S7.40
09.18.S7.44
Compression adjuster
8
12
Rebound adjuster
12
12
4,4 N/mm
4,2 N/mm
8 mm
7 mm
140 mm
155 mm
ca 800 ccm
ca 800 ccm
SAE 5
SAE 5
Spring
Spring preload
Air chamber length
Capacity per fork leg
Fork oil
117 kg (258 lbs)
01.18.S7.98
01.18.Q7.82
Compression adjuster
3
3
Rebound adjuster
5
4
Spring
66/260
63/260
Spring preload
17 mm
23 mm
NOTE FOR WHITE POWER FORKS:
The damping units in the left and the right fork leg are of different
design. Make sure not to mix them up in case of repair or service works.
TIGHTENING TORQUES - CHASSIS
Collar bolt front axle
M 10
40 Nm
(30 ft.lb)
Brake caliper front
M8
Loctite 243 + 25 Nm
(18 ft.lb)
Collar nut rear axle
M 20x1,5
80 Nm
(59 ft.lb)
Hex. nut swing arm bolt
M 14x1,5
100 Nm
(74 ft.lb)
Clamping bolt top triple clamp
M8
15 Nm
(11 ft.lb)
Clamping bolt bottom triple clamp
M8
20 Nm
(15 ft.lb)
Clamping bolts fork leg axle passage
M8
10 Nm
(7 ft.lb)
Other bolts chassis
M6
10 Nm
(7 ft.lb)
M8
25 Nm
(18 ft.lb)
M 10
45 Nm
(33 ft.lb)
10-21D
TECHNICAL SPECIFICATIONS – ENGINE
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearance
Valve diameter
Valve clearance cold
Crank shaft bearing
Conrod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
400/620 Supercompetition ‘99
400 LC4
620 LC4
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
398 ccm
609 ccm
89 / 64 mm
101 / 76 mm
10,8 : 1
10,4 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
IO 22° BTDC
EO 60° BBDC
IO 15° BTDC
EO 52° BBDC
IC 42° ABDC
EC 4° ATDC
IC 54° ABDC
EC 17° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,20 mm Exhaust: 0,20 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through 2 Eaten-oilpumps
see bellow #
1,6 liters (0,42 US gallons)
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless thyristor ignition with electronic advanced system type KOKUSAN
adjustment to max. 40 ° BTDC at 5000 rpm
adjustment to max. 36 ° BTDC at 5000 rpm
12V 110W
NGK DPR8 EA-9
0,90 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adj. screw open
Throttle valve
Starting jet
Performance restrictor
400 SC (20 kW)
400 SC
620 SC (20 kW)
620 SC
PHM 38 SD
300896
150
DR 266
45
K 51
3 rd
1,5 turn
40
45
slide stop 22 mm
PHM 38 SD
4894/6
190
DR 270 (DR 272)
45
K 51
2 nd
1,5 turn
40
45
–
PHM 40 SD
110996
155
DR 268
45
K 51
3 rd
1,5 turn
40
45
slide stop 26 mm
PHM 40 SD
4922
195
DR 272
45
K 51
2 nd
1,5 turn
40
45
–
10-22D
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Conrod bearing
Piston forged
Piston cast
Piston rings end gap
Valves
Oil pump
Bypaß valve
Clutch discs
Clutch springs
Transmission shafts
axial play..................................................0,03 - 0,12 mm
run out of crank stud .................................max. 0,04 mm
radial play ..................................................max. 0,05 mm
axial play ...................................................max. 1,00 mm
assembly clearance ...................................max. 0,12 mm
assembly clearance ...................................max. 0,05 mm
compression rings ......................................max. 0,60 mm
oil scraper ring ...........................................max. 0,80 mm
seat sealing intake......................................max. 1,50 mm
seat sealing exhaust ...................................max. 2,00 mm
run out of valve heads ...............................max. 0,03 mm
valve guides diameter ................................max. 7,05 mm
clearance outer rotor - housing..................max. 0,20 mm
clearance outer rotor - inner rotor..............max. 0,20 mm
minimum spring length..........................................25 mm
wear limit organic .................................................2,5 mm
minimum length ...........................34,5 mm (new 37 mm)
axial play......................................................0,1 - 0,4 mm
(0,001-0,005 in)
(0,002 in)
(0,002 in)
(0,04 in)
(0,005 in)
(0,002 in)
(0,023 in)
(0,031 in)
0,059 in)
(0,080 in)
(0,001 in)
(0,277 in)
(0,008 in)
(0,008 in)
(1 in)
(0,1 in)
(1,36 in - new 1,45 in)
(0,004 - 0,016 in)
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
Collar nut flywheel
Hexagon nut for inner clutch hub
Kickstarter stop bolt
AH bolts oil pump
Hexagon bolt camshaft gear
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
Cylinder head bolts
Collar nuts at cylinder base
Hexagon bolt chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Banjo bolts oil lines
Banjo bolt oil lines
Jet screw clutch cover
Bolt plug timing-chain tensioner
Counternuts valve adjusting screws
Spark plug
Crankshaft locking bolt
Engine fastening bolt
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
20x1,5
12x1 LH thread
18x1,5
12x1,5
6
10
6x25
6x50/M 6x55 (12.9)
6x65/M6x70 (8.8)
10
10
10
22x1,5
12x1,5
12x1,5
8x1
10x1
8x1
12x1,5
7x0,75
12x1,25
8
8
10
API: SF, SG, SH
TEMPERATURE
–
10W 40
10W 50
10W 60
0°C
32°F
+
15W 40
15W 50
15W 60
Loctite 243 +170
60
Loctite 648 + 80
50
Loctite 243 + 8
Loctite 243 + 35
8
20
8
50
40
Loctite 243 + 40
30
20
20
10
15
10
20
20
20
25
40
70
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
(125 ft.lb)
(44 ft.lb)
(59 ft.lb)
(37 ft.lb)
(6 ft.lb)
(26 ft.lb)
(6 ft.lb)
(15 ft.lb)
(6 ft.lb)
(37 ft.lb)
(30 ft.lb)
(30 ft.lb)
(22 ft.lb)
(15 ft.lb)
(15 ft.lb)
(7 ft.lb)
(11 ft.lb)
(7 ft.lb)
(15 ft.lb)
(15 ft.lb)
(15 ft.Ib)
18 ft.lb)
(30 ft.lb)
(51 ft.lb)
#
Engine oil
Use only oil brands (Shell Advance Ultra 4), which
meet quality requirements of API-classes SF, SG or SH
(informations on bottles) or higher. Both, mineral and
synthetic oils with above specifications can be used.
!
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
10-23D
TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 Supercompetition ‘99
400 SC
620 SC
Frame
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 43
Wheel travel front/rear
Rear suspension
295 / 320 mm (11,6 / 12,6 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc Ø 260 mm (10,2 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21 54R
Air pressure offroad
1,0 bar (14 psi)
Air press. road, driver only
1,5 bar (21 psi)
Tyres rear
140/80-18 70R
Air pressure offroad
1,2 bar (17 psi)
Air press. road, driver only
2,0 bar (28 psi)
Fuel tank capacity
9 liter (2,38 US gallons) of that 2,5 liter (0,66 US gallons) reserve
Final drive ratio
16:48 (14:50)
16:40 (15:50)
Chain
5/8 x 1/4 " O-Ring
Steering angle
62,5°
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Art.-Nr. 3.206.006 -E
Seat high
940 mm (37 in)
Ground clearance
375 mm (14,8 in)
Dead weight without fuel
122 kg (269 lbs)
STANDARD ADJUSTMENT - FORK
STANDARD-ADJUSTMENT - SHOCK ABSORBER
05.18.T7.81
01.18.T7.05
Compression adjuster
10
Compression adjuster
Rebound adjuster
12
Rebound adjuster
Spring
4,2 N/mm
Spring preload
6 mm (0,24 in)
Air chamber length
130 mm (5,1 in)
Capacity per fork leg
Fork oil
Spring
5
63 / 260
Spring preload
23 mm (0,9 in)
app. 700 ccm
SAE 5
NOTE FOR WHITE POWER FORKS:
The damping units in the left and the right fork leg are of different
design. Make sure not to mix them up in case of repair or service works.
Repair manual KTM LC4
3
TIGHTENING TORQUES - CHASSIS
Collar bolt front axle
M 10
40 Nm
(30 ft.lb)
Brake caliper front
M8
Loctite 243 + 25 Nm
(18 ft.lb)
Collar nut rear axle
M 20x1,5
80 Nm
(59 ft.lb)
Hex. nut swing arm bolt
M 14x1,5
100 Nm
(74 ft.lb)
Collar bolts handlebar clamps
M8
20 Nm
(15 ft.lb)
Collar bolts handlebar support
M 10
40 Nm
(30 ft.lb)
Clamping bolt top triple clamp
M8
23 Nm
(17 ft.lb)
Clamping bolt bottom triple clamp
M8
18 Nm
(13 ft.lb)
Clamping bolts fork leg axle passage
M8
10 Nm
(7 ft.lb)
Other bolts chassis
M6
10 Nm
(7 ft.lb)
M8
25 Nm
(18 ft.lb)
M 10
45 Nm
(33 ft.lb)
10-24D
TECHNICAL SPECIFICATIONS – ENGINE
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearance
Valve diameter
Valve clearance cold
Crankshaft bearing
Conrod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
620 LC4 COMPETITION ‘99
620 LC4 COMPETITION
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
609 cm3
101 / 76 mm
10,4 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
IO 15° BTDC
EO 52° BBDC
IC 54° ABDC
EC 17° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through 2 Eaten-oilpumps
see bellow #
2,1 liters including frame
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless thyristor ignition with electronic advanced system type SEM
adjustment to max. 32 ° BTDC at 6000 rpm
12V 130W
NGK DPR8 EA-9
0,90 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
Collar nut flywheel
Hexagon nut for inner clutch hub
Kickstarter stop bolt
AH bolts oil pump
Hexagon bolt camshaft gear
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
AH bolt cylinder head top sect.
Cylinder head bolts
Collar nuts at cylinder base
Hexagon bolt chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Banjo bolts oil lines
Banjo bolt oil lines
Jet screw clutch cover
Bolt plug timing-chain tensioner
Counternuts valve adjusting screws
Spark plug
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
20x1,5
Loctite 243 +170
12x1 LH thread
60
18x1,5
Loctite 648 + 80
12x1,5
50
6
Loctite 243 + 8
10
Loctite 243 + 35
6x25
8
6x50/M 6x55 (12.9)
20
6x65/M 6x70 (8.8)
8
10
50
10
40
10
Loctite 243 + 40
22x1,5
30
12x1,5
20
12x1,5
20
8x1
10
10x1
15
8x1
10
12x1,5
20
7x0,75
20
12
20
Nm (125 ft.lb)
Nm (44 ft.lb)
Nm (59 ft.lb)
Nm (37 ft.lb)
Nm
(6 ft.lb)
Nm (26 ft.lb)
Nm
(6 ft.lb)
Nm (15 ft.lb)
Nm
(6 ft.lb)
Nm (37 ft.lb)
Nm (30 ft.lb)
Nm (30 ft.lb)
Nm (22 ft.lb)
Nm (15 ft.lb)
Nm (15 ft.lb)
Nm
(7 ft.lb)
Nm (11 ft.lb)
Nm
(7 ft.lb)
Nm (15 ft.lb)
Nm (15 ft.lb)
Nm (15 ft.Ib)
10-25D
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Conrod bearing
Piston
Piston ring end gap
Valves
Oil pump
Bypaß valve
Clutch discs
Transmission shafts
Clutch
axial play..................................................0,03 - 0,12 mm
(0,001-0,005 in)
run out of crank stud .................................max. 0,08 mm
radial play ..................................................max. 0,05 mm
axial play ...................................................max. 1,00 mm
assembly clearance ...................................max. 0,12 mm
compression rings ......................................max. 0,60 mm
oil scraper ring ...........................................max. 0,80 mm
seat sealing intake......................................max. 1,50 mm
seat sealing exhaust ...................................max. 2,00 mm
run out of valve heads ...............................max. 0,05 mm
valve guides diameter ................................max. 7,05 mm
clearance outer rotor - housing..................max. 0,20 mm
clearance outer rotor - inner rotor..............max. 0,20 mm
minimum spring length..........................................25 mm
wear limit organic .................................................2,5 mm
axial play......................................................0,1 - 0,4 mm
minimum clutchspring length...........34,5 mm (new 37 mm)
(0,0031 in)
(0,0019 in)
(0,04 in)
(0,005 in)
(0,023 in)
(0,031 in)
0,059 in)
(0,079 in)
(0,002 in)
(0,277 in)
(0,008 in)
(0,008 in)
(1 in)
(0,1 in)
(0,004 in)
(1,36 in - new 1,45 in)
Art.-Nr. 3.206.006 -E
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
Repair manual KTM LC4
#
620 LC4 COMP.
24 kW
620 LC4 COMP.
37 kW
PHM 40 SD
110996
155
DR 268
45
K 51
3 rd
1,5 turn
40
45
slide stop 26 mm
PHM 40 SD
110996
155
DR 268
45
K 51
3 rd
1,5 turn
40
45
–
API: SF, SG, SH
TEMPERATUR
–
10W 40
10W 50
10W 60
+
0°C
32°F
15W 40
15W 50
15W 60
Engine oil
Use only oil brands,(Shell Advance Ultra 4) which
meet quality requirements of API-classes SF, SG or SH
(informations on bottles) or higher. Both, mineral and
synthetic oils with above specifications can be used.
!
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
10-26D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Wheel travel front/rear
Rear suspension
Front brake
Rear brake
Tyres front
Air press. road, driver only
Air press. road with passenger
Tyres rear
Air press. road, driver only
Air press. road with passenger
Fuel tank capacity
Final drive ratio
Chain
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
620 LC4 COMPETITION
Central chrome-moly-steel frame
WP Extreme
280 / 320 mm (11,0 / 12,6 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Disc brake with carbon-steel brake disc , brake caliper floated
brake disc Ø = 300 mm (11,8 in)
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
90/90-21 T63
1,5 bar (21 psi)
2,0 bar (28 psi)
130/80-18 T63
2,0 bar (28 psi)
2,2 bar (31 psi)
12 liter (3,2 US gallons)
of that 2,5 liter (0,7 US gallons) res
16:40
O-ring 5/8 x 1/4"
maintenance-free battery 12V 8Ah
62,5°
1510 ± 10 mm (59,4 ± 0,4 in)
955 mm (37,6 in)
335 mm (13,2 in)
133 kg (293 lbs)
211 kg (466 lbs)
335 kg (737 lbs)
350 kg (770 lbs)
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Capacity per fork leg
Fork oil
STANDARD-ADJUSTMENT - SHOCK ABSORBER
118 S 701
918 S 757
12
12
4,4 N/mm
10 mm
160 mm
app. 800 ccm
SAE 5
Compression adjuster
Rebound adjuster
Spring
Spring preload
Collar nut rear axle
Hex. nut swing arm bolt
Clamping bolt top triple clamp
Clamping bolt bottom triple clamp
Clamping bolts fork leg axle passage
Other bolts chassis
M 10
M8
M 20x1,5
M 14x1,5
M8
M8
M8
M6
M8
M 10
3
5
66/260
23 mm
NOTE FOR WP EXTREME FORKS:
The damping units in the left and the right fork leg are of
different design. Make sure not to mix them up in case of
repair or service works.
TIGHTENING TORQUES - CHASSIS
Collar bolt front axle
Brake caliper front
620 LC4 COMPETITION ‘99
40 Nm
25 Nm
+
80 Nm
100 Nm
15 Nm
20 Nm
10 Nm
10 Nm
25 Nm
45 Nm
(30 ft.lb)
(19 ft.lb)
Loctite 243
(59 ft.lb)
(74 ft.lb)
(11 ft.lb)
(15 ft.lb)
(7 ft.lb)
(7 ft.lb)
(19 ft.lb)
(33 ft.lb)
10-27D
TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘99
Engine
400 LC4-E
Design
640 LC4-E
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
Displacement
398 ccm
625 ccm
Bore / Stroke
89 / 64 mm
101 / 78 mm
Ratio
10,8 : 1
Fuel
11 : 1
unleaded premium gasoline with at least RON 95
Valve timing
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
Camshaft
249/1
Valve timing by 1 mm
IO 22° BTDC
valve clearance
EO 60° BBDC
IO 13° BTDC
EO 53° BBDC
EC 4° ATDC
IC 51° ABDC
EC 11° ATDC
IC 47° ABDC
Valve diameter
Intake: 36 mm
Valve clearance cold
Intake: 0,20 mm
Crank shaft bearing
Intake: 0,15 mm
Exhaust: 0,15 mm
2 cylinder roller bearing
Conrod bearing
needle bearing
Top end bearing
bronze bushing
Piston
forged/cast aluminium alloy
Piston rings
1 compression ring, 1 taper face ring, 1 oil scraper ring
Engine lubrication
two Eaten-oilpumps
Engine oil
see bellow #
Engine oil quantity
appr. 2,1 liters including frame
Primary ratio
straight geared spur wheels 30 : 81 teeth
Clutch
multi disc clutch in oil bath
Transmission
Art.-Nr. 3.206.006 -E
Exhaust: 30 mm
Exhaust: 0,20 mm
5-speed claw shifted
Gear ratio
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
Ignition system
contactless DC-CDI ignition with digital advanced system type KOKUSAN
Ignition timing
adjustment to max. 38° BTDC at 6000 rpm
Generator
12V 200W
Spark plug
NGK DPR8 EA-9
Spark plug gap
0,90 mm
Cooling system
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
Cooling liquid
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
Starting equipment
electric starter and kickstarter
Repair manual KTM LC4
#
Engine oil
API: SF, SG, SH
TEMPERATURE
–
10W 40
10W 50
10W 60
0°C
32°F
+
15W 40
15W 50
15W 60
Use only oil brands (Shell Advance Ultra 4), which
meet quality requirements of API-classes SF, SG or SH
(informations on bottles) or higher. Both, mineral and
synthetic oils with above specifications can be used.
!
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
10-28D
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture adj. screw open
Throttle valve
Starting jet
Performance restrictor
400 LC4
25 kW
400 LC4
31 kW
640 LC4
25 kW
640 LC4
37 kW
PHM 38 ND
100197
130
AR 264
50
K 23
2 nd
1,5 turn
50/1
45 (50, 55)
slide stop 51 mm
PHM 38 ND
100197
130
AR 264
50
K 23
2 nd
1,5 turn
50/1
45 (50, 55)
–
BST40-225
080298
142,5
689 X-6
45
6G5
3 rd
–
–
–
slide stop 17 mm
BST40-225
090298
142,5
689 X-6
45
6G5
3 rd
–
–
–
–
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
M 20x1,5
Hexagon nut flywheel
M 16x1,25 LH thread
Hexagon nut for inner clutch hub
M 18x1,5
Loctite 243 + 170 Nm (125 ft.lb)
150 Nm (110 ft.lb)
80 Nm (59 ft.lb)
Kickstarter stop bolt
M 12x1,5
Allen head bolts oil pump
M6
50 Nm (37 ft.lb)
Hexagon bolt camshaft gear
M 10
Loctite 243 + 35 Nm (26 ft.lb)
Allen head bolts outer race
M 6x12/M 6x12,5
Loctite 648 + 18 Nm (13 ft.lb)
Allen head bolt cylinder head top sect.
M 6x50/M 6x55 (12.9)
Allen head bolt cylinder head top sect.
M 6x25/M 6x65/M 6x70 (8.8)
Cylinder head bolts
M 10
50 Nm (37 ft.lb)
Collar nuts at cylinder base
M 10
40 Nm (30 ft.lb)
Hexagon bolt chain sprocket
M 10
Loctite 243 + 40 Nm (30 ft.lb)
Oil drain plug
M 22x1,5
Magnetic plug
M 12x1,5
20 Nm (15 ft.lb)
Plug bypass valve
M 12x1,5
20 Nm (15 ft.lb)
Crankshaft locating bolt
M8
25 Nm (18 ft.lb)
Hollow bolts oil lines
M 8x1
10 Nm (7 ft.lb)
Hollow bolts oil lines
M 10x1
15 Nm (11 ft.lb)
Jet screw clutch cover
M8
Loctite 243 + 8 Nm (6 ft.lb)
20 Nm (15 ft.lb)
8 Nm (6 ft.lb)
30 Nm (22 ft.lb)
10 Nm (7 ft.lb)
Bolt plug timing-chain tensioner
M 12x1,5
20 Nm (15 ft.lb)
Counternuts valve adjusting screws
M 7x0,75
20 Nm (15 ft.lb)
Engine fastening bolt
M8
40 Nm (30 ft.lb)
M 10
70 Nm (52 ft.lb)
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
axial play ....................0,03 - 0,12 mm (0,0012 - 0,0047 in)
run out of crank stud ..................max. 0,04 mm (0,0031 in)
Conrod bearing
radial play .....................................max. 0,05 mm (0,002 in)
axial play .......................................max. 1,00 mm (0,043 in)
Cylinder
bore diameter..........................max. 101,04 mm (3,9779 in)
Piston
assembly clearance ......................max. 0,12 mm (0,0047 in)
Piston ring end gap
compression rings........................max. 0,80 mm (0,0315 in)
oil scraper ring...............................max. 1,0 mm (0,0394 in)
Valves
seat sealing intake .......................max. 1,50 mm (0,0591 in)
seat sealing exhaust ....................max. 2,00 mm (0,0788 in)
run out of valve heads ................max. 0,05 mm (0,0019 in)
valve guides diameter..................max. 7,05 mm (0,2778 in)
Oil pump
clearance outer rotor - housing ......max. 0,20 mm (0,0079 in)
Bypaß valve
minimum spring length .............................25 mm (0,985 in)
Clutch
clutchspring length...min. 34,5 mm (1,36 in), new 37 mm (1,458 in)
Camshaft
diameter of bearing bolt.............min. 19,97 mm (0,7868 in)
(needle bearing)
Transmission shafts
axial play........................0,1 – 0,4 mm (0,0039 – 0,0158 in)
clearance outer rotor - inner rotor .....max. 0,20 mm (0,0079 in)
wear limit organic............................min. 2,5 mm (0,0985 in)
10-29D
TECHNICAL SPECIFICATIONS - CHASSIS 400 LC4 / 640 LC4 (R) / SUPERMOTO ‘99
400 LC4 / 640 LC4
640 Supermoto
Frame
Central chrome-moly-steel frame
Fork
WP Extreme
Wheel travel front/rear
280 / 320 mm (11 / 12.6 in)
Rear suspension
Disc brake with carbon-steel brake disc 300 mm (11.8 in), brake caliper floated
Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated
Rear brake
Tyres front
90/90-21
120/70-17
90/90-21
Air press. road, driver only
1.5 bar (22 psi)
2.0 bar (29 psi
1.5 bar (22 psi)
Air press. road with passenger
2.0 bar (29 psi)
2.2 bar (31 psi)
2.0 bar (29 psi)
140/80-18
160/60-17
140/80-18
Air press. road, driver only
2.0 bar (29 psi)
2.2 bar (31 psi)
2.0 bar (29 psi)
Air press. road with passenger
2.2 bar (31 psi)
2.4 bar (34 psi)
2.2 bar (31 psi)
Tyres rear
Fuel tank capacity
Final drive ratio
12 or 18 liter (3.2 or 4.8 US gallons), 2.5 liter (0,6 US gallons) reserve
400 LC4 - 15:45
640 LC4 - 16:42
17:40
16:42
Chain
O – Ring 5/8 x 1/4"
Battery
maintenance-free battery 12V 8Ah
Steering angle
62,5 °
63°
Wheel base
62.5°
1510 ± 10 mm (59.4 ± 0.4 in)
Seat high
955 mm (37.6 in)
935 mm (36.8 in)
Ground clearance
375 mm (14.8 in)
355 mm (13.9 in)
Dead weight without fuel
Art.-Nr. 3.206.006 -E
250 / 290 mm (10 / 11.4 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear- swing-arm with needle bearing
Front brake
136kg (300 lbs)
137 kg (302 Ibs)
Max. permissible front axle load
211 kg (465 lbs)
Max. permissible rear axle load
335 kg (740 lbs)
Max. permissible loaden weight
350 kg (773 lbs)
STANDARD ADJUSTMENT - FORK
918S776
12
12
Compression adjuster
12
12
Rebound adjuster
4,4 N/mm
4,4 N/mm
Rebound adjuster
Spring
Spring preload
10 mm (0,4 in)
15 mm (0,6 in)
Air chamber length
160 mm (6,3 in)
160 mm (6,3 in)
app. 800 ccm
app. 800 ccm
SAE 5
SAE 5
Capacity per fork leg
Fork oil
Spring
Spring preload
TIGHTENING TORQUES - CHASSIS
Collar bolt front axle
M 10
135 kg (298 Ibs)
STANDARD-ADJUSTMENT - SHOCK ABSORBER
918S757
Compression adjuster
Repair manual KTM LC4
400 LC4 R / 640 LC4 R
40 Nm
(30 ft.lb)
Loctite 243 + 25 Nm
(20 ft.lb)
Brake caliper front
M8
Collar nut rear axle
M 20x1,5
80 Nm
(60 ft.lb)
Hexagon nut swingarm bolt
M 14x1,5
100 Nm
(74 ft.lb)
Clamping bolt upper triple clamp
M8
15 Nm
(11 ft.lb)
Clamping bolt lower triple clamp
M8
20 Nm
(15 ft.lb)
Clamping bolts fork stubs
M8
10 Nm
(7 ft.lb)
Other bolts chassis
M6
10 Nm
(7 ft.lb)
M8
25 Nm
(20 ft.lb)
M 10
45 Nm
(33 ft.lb)
118S701
118Q784
3
3
5
4
66/260
63/260
23 mm (0,9 in)
23 mm (0,9 in)
10-30D
TECHNICAL DATA – ENGINE 640 LC4-E ADVENTURE R ‘99
Engine
640 LC4-E
Design
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
Displacement
625 ccm
Bore / Stroke
101 / 78 mm
Ratio
11,0 : 1
Fuel
unleaded premium gasoline with a least RON 95
Valve timing
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
Camshaft
249° (249/1)
Valve timing by 1 mm
IO 13° BTDC
EO 53° BBDC
valve clearance
IC 51° ABDC
EC 11° ATDC
Valve diameter
Intake: 36 mm
Valve clearance cold
0,15 mm
Crank shaft bearing
Exhaust: 30 mm
Exhaust: 0,15 mm
2 cylinder roller bearing
Conrod bearing
needle bearing
Top end bearing
bronze bushing
Piston
cast aluminium alloy
Piston rings
1 compression ring, 1 taper face ring, 1 oil scraper ring
Engine lubrication
two Eaten-oilpumps
Engine oil
see below #
Engine oil quantity
appr. 2,1 liters including frame
Primary ratio
straight geared spur wheels 30 : 81 teeth
Clutch
multi disc clutch in oil bath
Transmission
5-speed claw shifted
Gear ratio
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
Ignition system
contactless DC-CDI ignition with digital advanced system type KOKUSAN
Ignition timing
adjustment to max. 38° BTDC at 6000 rpm
Generator
12V 200W
Spark plug
NGK DPR8 EA-9
Spark plug gap
0,90 mm
Cooling system
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
Cooling liquid
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
Starting equipment
electric starter and kickstarter
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixt. adj. screw open
Throttle valve
Starting jet
Permormance restrictor
640 ADVENTURE
640 ADVENTURE
25 kW
36 kW
BST40-225
080298
142,5
689 X-6
45
6G5
3 rd
–
–
–
slide stop 17 mm
BST40-225
090298
142,5
689 X-6
45
6G5
3 rd
–
–
–
–
10-31D
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
M 20x1,5
Hexagon nut flywheel
M 16x1,25 LH thread
Loctite 243 + 170 Nm (125 ft.lb)
Hexagon nut for inner clutch hub
M 18x1,5
150 Nm (110 ft.lb)
80 Nm (59 ft.lb)
Kickstarter stop bolt
M 12x1,5
Allen head bolts oil pump
M6
50 Nm (37 ft.lb)
Hexagon bolt camshaft gear
M 10
Loctite 243 + 35 Nm (26 ft.lb)
Allen head bolts outer race
M 6x12/M 6x12,5
Loctite 648 + 18 Nm (13 ft.lb)
Allen head bolt cylinder head top sect.
M 6x50/M 6x55 (12.9)
Allen head bolt cylinder head top sect.
M 6x25/M 6x65/M 6x70 (8.8)
Cylinder head bolts
M 10
50 Nm (37 ft.lb)
Collar nuts at cylinder base
M 10
40 Nm (30 ft.lb)
Hexagon bolt chain sprocket
M 10
Loctite 243 + 40 Nm (30 ft.lb)
Oil drain plug
M 22x1,5
Magnetic plug
M 12x1,5
20 Nm (15 ft.lb)
Plug bypass valve
M 12x1,5
20 Nm (15 ft.lb)
Crankshaft locating bolt
M8
25 Nm (18 ft.lb)
Hollow bolts oil lines
M 8x1
10 Nm (7 ft.lb)
Hollow bolts oil lines
M 10x1
15 Nm (11 ft.lb)
Jet screw clutch cover
M8
Loctite 243 + 8 Nm (6 ft.lb)
20 Nm (15 ft.lb)
8 Nm (6 ft.lb)
30 Nm (22 ft.lb)
10 Nm (7 ft.lb)
Bolt plug timing-chain tensioner
M 12x1,5
20 Nm (15 ft.lb)
Counternuts valve adjusting screws
M 7x0,75
20 Nm (15 ft.lb)
Engine fastening bolt
M8
40 Nm (30 ft.lb)
M 10
70 Nm (52 ft.lb)
Art.-Nr. 3.206.006 -E
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
axial play ....................0,03 - 0,12 mm (0,0012 - 0,0047 in)
run out of crank stud ..................max. 0,08 mm (0,0031 in)
Conrod bearing
radial play .....................................max. 0,05 mm (0,002 in)
axial play .......................................max. 1,10 mm (0,043 in)
Cylinder
bore diameter..........................max. 101,04 mm (3,9779 in)
Piston
assembly clearance ......................max. 0,12 mm (0,0047 in)
Piston ring end gap
compression rings........................max. 0,80 mm (0,0315 in)
oil scraper ring...............................max. 1,0 mm (0,0394 in)
Valves
seat sealing intake .......................max. 1,50 mm (0,0591 in)
seat sealing exhaust ....................max. 2,00 mm (0,0788 in)
run out of valve heads ................max. 0,05 mm (0,0019 in)
valve guides diameter..................max. 7,05 mm (0,2778 in)
Oil pump
clearance outer rotor - housing ......max. 0,20 mm (0,0079 in)
Bypaß valve
minimum spring length .............................25 mm (0,985 in)
Clutch
clutchspring length...min. 34,5 mm (1,36 in), new 37 mm (1,458 in)
Camshaft
diameter of bearing bolt.............min. 19,97 mm (0,7868 in)
(needle bearing)
Transmission shafts
axial play........................0,1 – 0,4 mm (0,0039 – 0,0158 in)
clearance outer rotor - inner rotor .....max. 0,20 mm (0,0079 in)
Repair manual KTM LC4
Wear limit organic ...........................min. 2,5 mm (0,0985 in)
#
Engine oil
API: SF, SG, SH
TEMPERATURE
–
10W 40
10W 50
10W 60
0°C
32°F
+
15W 40
15W 50
15W 60
Use only oil brands, which meet quality requirements
of API-classes SF, SG or SH (informations on bottles)
or higher. Both, mineral and synthetic oils with above
specifications can be used.
!
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
10-32D
TECHNICAL SPECIFICATIONS - CHASSIS 640 ADVENTURE R ‘99
640 ADVENTURE R
Frame
Central chrome-moly-steel frame
Fork
WP-Extreme Ø 50 mm
Wheel travel front/rear
Rear suspension
300 / 320 mm (11,8 / 12,6 in)
Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing
Front brake
Disc brake with carbon-steel brake disc 300 mm (11,8 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc 220 mm (8,7 in), brake caliper floated
Tyres front
90/90 - 21 54S Enduro 3
Air press. road, driver only
1,5 bar (22 psi)
Air press. road with passenger
2,0 bar (29 psi)
Tyres rear
140/80 - 18 70R Enduro 3
Air press. road, driver only
2,0 bar (29 psi)
Air press. road with passenger
2,2 bar (31 psi)
Fuel tank capacity
28 liter (7,4 US gallons),
Final drive ratio
3,8 liter (1 US gallons) reserve
16:40 t
Chain
O – Ring 5/8 x 1/4"
Battery
maintenance-free battery 12V 8Ah
Steering angle
62,5 °
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
940 mm (37 in)
Ground clearance
320 mm (12,6 in)
Dead weight without fuel
154 kg (340 lbs)
Max. permissible front axle load
150 kg (331 lbs)
Max. permissible rear axle load
230 kg (507 lbs)
Max. permissible loaden weight
380 kg (839 lbs)
STANDARD ADJUSTMENT - FORK
09.18.S7.55
Compression adjuster
14
Rebound adjuster
12
Spring
4,4 N/mm
Spring preload
10 mm (0,4 in)
Air chamber length
155 mm (5,9 in)
Capacity per fork leg
app. 800 ccm
Fork oil
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
01.18.R7.97
Compression adjuster
3
Rebound adjuster
5
Spring
70/260
Spring preload
23 mm (0,9 in)
TORQUES
Collar bolt front axle
M 10
Brake caliper front
M8
40 Nm
(30 ft.lb)
Loctite 243 + 25 Nm
(18 ft.lb)
Collar nut rear axle
M 20x1,5
80 Nm
(59 ft.lb)
Hexagon nut swingarm bolt
M 14x1,5
100 Nm
(74 ft.lb)
Clamping bolt upper triple clamp
M8
15 Nm
(11 ft.lb)
Clamping bolt lower triple clamp
M8
20 Nm
(15 ft.lb)
Clamping bolts fork stubs
M8
10 Nm
(7 ft.lb)
Other bolts chassis
M6
10 Nm
(7 ft.lb)
M8
25 Nm
(19 ft.lb)
M 10
45 Nm
(33 ft.lb)
10-33D
TECHNICAL DATA – ENGINE
Art.-Nr. 3.206.006 -E
Type
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Quantity of engine oil
Engine oil
Primary ratio
Clutch
Transmission
Gear ratio
KTM 640 DUKE ‘99
640 LC4-E
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
625 ccm
101 / 78 mm
11,0 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249° (249/1)
IO 13° BTDC
EO 53° BBDC
IC 53° ABDC
EC 11° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0.15 mm Exhaust: 0.15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
2 Eaton-Oilpumps
see below #
2.1 liters including frame
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
contactless DC- CDI ignition with digital advanced system type KOKUSAN
adjustment to max. 38° BTDC at 6000 rpm
12V 200W
NGK DPR8 EA-9
0.90 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F)
electric starter, kick starter
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
BASIC CARBURETOR SETTING
#
API: SF, SG, SH
Repair manual KTM LC4
640 DUKE
40 kW
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
BST40-225
100299
145
689 X-6
45
6G5
3 rd
2,25 turn
TEMPERATURE
–
10W 40
10W 50
10W 60
+
0°C
32°F
15W 40
15W 50
15W 60
Engine oil
Use only oil brands (Shell Advance Ultra 4), which
meet quality requirements of API-classes SF, SG or SH
(informations on bottles) or higher. Both, mineral and
synthetic oils with above specifications can be used.
!
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
10-34D
TIGHTENING TORQUES - ENGINE
Hexagon nut at primary gear
M 20x1,5
Hexagon nut flywheel
M 16x1,25 LH thread
Hexagon nut for inner clutch hub
M 18x1,5
Loctite 243 + 170 Nm (125 ft.lb)
150 Nm (110 ft.lb)
Loctite 243 + 80 Nm (59 ft.lb)
Kickstarter stop bolt
M 12x1,5
Allen head bolts oil pump
M6
50 Nm (37 ft.lb)
Hexagon bolt camshaft gear
M 10
Loctite 243 + 35 Nm (26 ft.lb)
Allen head bolts outer race
M 6x12/M 6x12,5
Loctite 648 + 18 Nm (13 ft.lb)
Allen head bolt cylinder head top sect.
M 6x50/M 6x55 (12.9)
Allen head bolt cylinder head top sect.
M 6x25/M 6x65/M 6x70 (8.8)
Cylinder head bolts
M 10
50 Nm (37 ft.lb)
Collar nuts at cylinder base
M 10
40 Nm (30 ft.lb)
Hexagon bolt chain sprocket
M 10
Loctite 243 + 40 Nm (30 ft.lb)
Oil drain plug
M 22x1,5
Magnetic plug
M 12x1,5
20 Nm (15 ft.lb)
Plug bypass valve
M 12x1,5
20 Nm (15 ft.lb)
Crankshaft locating bolt
M8
25 Nm (18 ft.lb)
Hollow bolts oil lines
M 8x1
10 Nm (7 ft.lb)
Hollow bolts oil lines
M 10x1
15 Nm (11 ft.lb)
Jet screw clutch cover
M8
Loctite 243 + 8 Nm (6 ft.lb)
20 Nm (15 ft.lb)
8 Nm (6 ft.lb)
30 Nm (22 ft.lb)
10 Nm (7 ft.lb)
Bolt plug timing-chain tensioner
M 12x1,5
20 Nm (15 ft.lb)
Counternuts valve adjusting screws
M 7x0,75
20 Nm (15 ft.lb)
Engine fastening bolt
M8
40 Nm (30 ft.lb)
M 10
70 Nm (52 ft.lb)
ASSEMBLY CLEARANCE, WEAR LIMIT
Crankshaft
axial play ....................0,03 - 0,12 mm (0,0012 - 0,0047 in)
run out of crank stud ..................max. 0,08 mm (0,0031 in)
Conrod bearing
radial play .....................................max. 0,05 mm (0,002 in)
axial play .......................................max. 1,10 mm (0,043 in)
Cylinder
bore diameter..........................max. 101,04 mm (3,9779 in)
Piston
assembly clearance ......................max. 0,12 mm (0,0047 in)
Piston ring end gap
compression rings........................max. 0,80 mm (0,0315 in)
oil scraper ring...............................max. 1,0 mm (0,0394 in)
Valves
seat sealing intake .......................max. 1,50 mm (0,0591 in)
seat sealing exhaust ....................max. 2,00 mm (0,0788 in)
run out of valve heads ................max. 0,05 mm (0,0019 in)
valve guides diameter..................max. 7,05 mm (0,2778 in)
Oil pump
clearance outer rotor - housing ......max. 0,20 mm (0,0079 in)
Bypaß valve
minimum spring length .............................25 mm (0,985 in)
Clutch
clutchspring length...min. 34,5 mm (1,36 in), new 37 mm (1,458 in)
Camshaft
diameter of bearing bolt.............min. 19,97 mm (0,7868 in)
(needle bearing)
Transmission shafts
axial play........................0,1 – 0,4 mm (0,0039 – 0,0158 in)
clearance outer rotor - inner rotor .....max. 0,20 mm (0,0079 in)
Wear limit organic ...........................min. 2,5 mm (0,0985 in)
10-35D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Rear suspension
Shock absorber
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Front brake
Rear brake
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
Final drive ratio
Chain
Lamps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
KTM 640 DUKE ‘99
Central chrome-moly-steel frame
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Top adjuster 518T780
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . . . . . driver only = 14, with passenger = 14
fork leg projection upper fork bridge . . . . . . . . 3 mm (0.12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 750 ccm (45 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785
rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in)
standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5
standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3
spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260
Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated
front: 120/70 R 17 58H
rear: 160/60 R 17 69H
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
12 liter (3,2 US gallons), out of this 2,5 liter (0,6 US gallons) reserve
17 : 38
o-ring 5/8 x 1/4"
low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
64,2°
1460 ± 15 mm (57.5 ± 0.6 in)
860 mm (33.9 in)
250 mm (9.9 in)
145 kg (3 lbs)
150 kg (2 lbs)
200 kg (4 lbs)
350 kg (773 lbs)
TIGHTENING TORQUES - CHASSIS
Front axle
Rear axle
Hex. nut swing arm bolt
Clamping bolt upper fork bridge
Clamping bolt lower fork bridge
Clamping bolts fork stubs
AH bolts front brake caliper
AH bolt rear brake caliper support
Collar nuts chain tension eccentrics
Collar nut conrod pro lever system
Bolts handlebar clamps
Bolt adjusting ring spring preload shock absorber
Other bolts chassis
M 17
M20x1.5
M14x1.5
M8
M8
M8
M10x1,25
M10
M10
M12x1,75
M8
M6
M6
M8
M10
40
80
100
15
15
15
Loctite 243 + 40
40
40
60
25
8
10
25
45
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
(30 ft.lb)
(59 ft.lb)
(74 ft.lb)
(11 ft.lb)
(11 ft.lb)
(11 ft.lb)
(30 ft.lb)
(30 ft.lb)
(30 ft.lb)
(44 ft.lb)
(15 lb.ft)
(6 ft.lb9
(7 ft.lb)
(22 ft.lb)
(33 ft.lb)
10-36D
TECHNICAL SPECIFICATIONS – ENGINE
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Conrod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
400/620 SC, Supermoto 2000
400 LC4
620 LC4
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
398 ccm
609 ccm
89 / 64 mm
101 / 76 mm
10,8 : 1
10,4 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
IO 22° BTDC
EO 60° BBDC
IO 15° BTDC
EO 52° BBDC
IC 42° ABDC
EC 4° ATDC
IC 54° ABDC
EC 17° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,20 mm Exhaust: 0,20 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through 2 Eaten-oilpumps with oil sump
see below #
1,6 liters (0,42 US gallons)
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless thyristor ignition with electronic advanced system type KOKUSAN 4K-3
adjustment to max. 40 ° BTDC at 5000 rpm
adjustment to max. 36 ° BTDC at 5000 rpm
12V 110W
NGK DPR8 EA-9
0,90 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
BASIC CARBURETOR SETTING
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
400 SC (20 kW)
400 SC
620 SC (20 kW)
620 SC
PHM 38 SD
300896
150
DR 266
45
K 51
3 rd
1,5 turn
40
45
slide stop 22 mm
PHM 38 SD
4894/6
190
DR 270 (DR 272)
45
K 51
2 nd
1,5 turn
40
45
–
PHM 40 SD
110996
155
DR 268
45
K 51
3 rd
1,5 turn
40
45
slide stop 26 mm
PHM 40 SD
4922
195
DR 272
45
K 51
2 nd
1,5 turn
40
45
–
10-37D
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
axial play..................................................0.03 - 0.12 mm
run out of crank stud .................................max. 0.04 mm
radial play ..................................................max. 0.05 mm
axial play ...................................................max. 1.00 mm
assembly clearance ...................................max. 0.12 mm
assembly clearance ...................................max. 0.05 mm
compression rings ......................................max. 0.60 mm
oil scraper ring ...........................................max. 0.80 mm
seat sealing intake......................................max. 1.50 mm
seat sealing exhaust ...................................max. 2.00 mm
run out of valve heads ...............................max. 0.03 mm
valve guides diameter ................................max. 7.05 mm
clearance outer rotor - housing..................max. 0.20 mm
clearance outer rotor - inner rotor..............max. 0.20 mm
minimum spring length..........................................25 mm
wear limit organic .................................................2.5 mm
minimum length ...........................34.5 mm (new 37 mm)
axial play......................................................0.1 - 0.4 mm
Conrod bearing
Piston forged
Piston cast
Piston rings end gap
Valves
Oil pump
Bypaß valve
Clutch discs
Clutch springs
Transmission shafts
#
Art.-Nr. 3.206.006 -E
API: SG, SH
TEMPERATURE
–
10W 40
10W 50
+
0°C
32°F
15W 40
15W 50
Engine oil
Use only synthetic oil (Shell Advance Ultra 4), which meet
quality requirements of API-classes SG or SH (informations
on bottles) or higher.
!
Repair manual KTM LC4
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR.
(0.001-0.005 in)
(0.002 in)
(0.002 in)
(0.04 in)
(0.005 in)
(0.002 in)
(0.023 in)
(0.031 in)
0.059 in)
(0.080 in)
(0.001 in)
(0.277 in)
(0.008 in)
(0.008 in)
(1 in)
(0.1 in)
(1.36 in - new 1.45 in)
(0.004 - 0.016 in)
10-38D
TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SC, Supermoto
400/620 SC
620 Supermoto
Frame
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 43
Wheel travel front/rear
Rear suspension
Front brake
Rear brake
Tyres front
295 / 320 mm (11.6 / 12.6 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Disc brake with carbon-steel brake disc
Disc brake with carbon-steel brake disc
Ø 260 mm (10.2 in), brake caliper floated
Ø 320 mm (12.6 in), brake caliper floated
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
90/90-21 Pirelli MT 21
120/70-17 Pirelli MT 60
Air pressure offroad
1.0 bar (14 psi)
–
Air press. road, driver only
1.5 bar (21 psi)
2.0 bar (28 psi)
140/80-18 Pirelli MT 21
160/60-17 Pirelli MT 60
Air pressure offroad
1.2 bar (17 psi)
–
Air press. road, driver only
2.0 bar (28 psi)
2.2 bar (31 psi)
Tyres rear
Fuel tank capacity
Final drive ratio
9 liter (2.38 US gallons) of that 2.5 liter (0.66 US gallons) reserve
400: 16:48
620: 16:40
Chain
17:38
5/8 x 1/4 " O-Ring
Steering angle
62.5°
Wheel base
1510 ± 10 mm (59.4 ± 0.4 in)
Seat height
940 mm (37 in)
920 mm (36 in)
Ground clearance
375 mm (14.8 in)
355 mm (14 in)
Dead weight without fuel
122 kg (269 lbs)
123 kg (271 lbs)
STANDARD ADJUSTMENT - FORK
STANDARD ADJUSTMENT - SHOCK ABSORBER
05.18.U7.82
01.18.T7.05
Compression adjuster
14
Compression adjuster
Rebound adjuster
14
Rebound adjuster
Spring
Spring preload
Air chamber length
Capacity per fork leg
Fork oil
2000
4.2 N/mm
7 mm (0.28 in)
120 mm (4.72 in)
app. 420 ccm
SAE 5
Spring
Spring preload
3
5
63 / 260
23 mm (0.9 in)
10-39D
Art.-Nr. 3.206.006 -E
TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2000
Type
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Quantity of engine oil
Engine oil
Primary ratio
Clutch
Transmission
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
400 LC4-E
640 LC4-E
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
398 ccm
624,6 ccm
89 / 64 mm
101 / 78 mm
10,8 : 1
11,0 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
(249/1)
IO 22° BTDC
EO 60° BBDC
IO 13° BTDC
EO 53° BBDC
IC 42° ABDC
EC 4° ATDC
IC 51° ABDC
EC 11° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0.20 mm Exhaust: 0.20 mm
Intake: 0.15 mm Exhaust: 0.15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
2 Eaton-Oilpumps
see table
2.1 liters including frame
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
contactless DC- CDI ignition with digital advanced system type KOKUSAN
adjustment to max. 38° BTDC at 6000 rpm
12V 200W
DPR8 EA9
0.9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F)
electric starter, kick starter
Engine oil
API: SG, SH
TEMPERATURE
Repair manual KTM LC4
–
0°C
32°F
10W 40
10W 50
Use only synthetic oils, which meet quality
requirements of API-classes SG or SH (informations
on bottles) or higher.
+
!
POOR
15W 40
15W 50
GEAR RATIOS
Primary
ratio
30:81
Transmission
1st gear
2nd gear
3rd gear
4th gear
5th gear
14:35
15:24
18:21
20:19
22:18
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
Original final
drive ratio
Available chain
drive sprockets
Available final
drive sprockets
15:45
16:42
17:38
17:42
15 t
16 t for chain
17 t 5/8 x 1/4"
38
40
42
45
48
t
t for chain
t 5/8 x 1/4"
t
t
10-40D
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm
run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm
radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm
oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm
seat sealing intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm
seat sealing exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm
run out of valve heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
valve guides diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm
clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm
Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm)
wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm
diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm
Connecting rod bearing
Cylinder 400
Cylinder 640
Piston forged
Piston cast
Piston rings end gap
Valves
Oil pumps
Bypaß valve
Clutch
Camshaft
Transmission shafts
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
400 LC4-E
400 LC4-E
400 LC4-E
25 kW
31 kW
USA
PHM 38 ND
100197
130
AR 264
50
K 23
2. from top
1.5 turns
50/1
45(50,55)
slide stop 51mm
PHM 38 ND
100197
130
AR 264
50
K 23
2. from top
1,5 turns
50/1
45(50,55)
–
BST40-225
090298
142,5
689 X-6
45
6G5
3. from top
2,25 turns
–
–
–
640 LC4-E, Adventure
640 LC4-E, Adventure
640 Duke
25 kW
36 kW
40 kW
BST40-225
080298
142,5
689 X-6
45
6G5
3. from top
2,25 turns
–
–
slide stop 17mm
BST40-225
090298
142,5
689 X-6
45
6G5
3. from top
2,25 turns
–
–
–
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
BST40-225
100299
145
689 X-6
45
6G5
3. from top
2,25 turns
–
–
–
10-41D
TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2000
400 LC4-E
640 LC4-E
Frame
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 43
Wheel travel front/rear
Rear suspension
270 / 300 mm (10,6 / 11,8 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc, brake caliper floated
Brake Disk front
Rear brake
640 LC4-E SUPERMOTO
Ø 300 mm (11,8 in)
Ø 320 mm ( 12,6 in)
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21
120/70-17
Air press. road, driver only
1,5 bar (21 psi)
2,0 bar (28 psi)
Air press. road, with passenger
2,0 bar (28 psi)
2,2 bar (31 psi)
140/80-18
160/60-17
Air press. road, driver only
2,0 bar (28 psi)
2,2 bar (31 psi)
Air press. road, with passenger
2,2 bar (31 psi)
2,4 bar (34 psi)
Tyres rear
Fuel tank capacity
11 liter (2,9 US gallons) / 18 liter (4,75 US gallons)
2,5 liter (0,66 US gallons) reserve
Art.-Nr. 3.206.006 -E
Final drive ratio
15:45
17:42
Chain
Lamps
5/8 x 1/4 " O-Ring
head light . . . . . . . . . . . . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)
parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illumination . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
Battery
12V 8Ah
Steering angle
62,5°
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
Repair manual KTM LC4
16:42
935 mm (36,8 in)
915 mm (36 in)
Ground clearance
355 mm (14 in)
335 mm (13,2 in)
Dead weight without fuel
136 kg (300 lbs)
137 kg (302 lbs)
Max. permissable front axe load
211 kg (466 lbs)
Max. permissable rear axe load
335 kg (740 lbs)
Max. permissable laden weigth
350 kg (773 lbs)
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Capacity per fork leg
Fork oil
WP 0518U790
20
12
4,4 N/mm
6 mm (0,25 in)
150 mm (5,9 in)
ca 410 ccm
SAE5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload
WP 0118U707
6
7
66 / 260
27 mm (1,1 in)
10-42D
TECHNICAL SPECIFICATIONS - CHASSIS LC4 ADVENTURE R 640 2000
LC4 Adventure R 640
Frame
Central chrome-moly-steel frame
Fork
WP Extreme
Wheel travel front/rear
Rear suspension
280/320 mm (11/12,6 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc Ø 300 mm (11,8 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21 Enduro3
Air pressure offroad
1,5 bar (21 psi)
Air press. road, driver only
2,0 bar (29 psi)
Tyres rear
140/80-18 Enduro3
Air press. road, driver only
2,0 bar (29 psi)
Air press. road, with passenger
2,2 bar (32 psi)
Fuel tank capacity
28 liter (7,4 US gallons) of that 3,5 liter (1 US gallons) reserve
Final drive ratio
16 : 42
Chain
5/8 x 1/4 " O-Ring
Battery
maintenance-free battery
Steering angle
12V 8Ah
62,5°
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
955 mm (37,7 in)
Ground clearance
375 mm (14,8 in)
Dead weight without fuel
154 kg (340 lbs)
Max. permissible front axle load
150 kg (331 lbs)
Max. permissible rear axle load
230 kg (507 lbs)
Max. permissible laden weight
380 kg (839 lbs)
STANDARD ADJUSTMENT - FORK
STANDARD-ADJUSTMENT - SHOCK ABSORBER
09.18.S7.55
01.18.R7.97
Compression adjuster
14
Compression adjuster
3
Rebound adjuster
12
Rebound adjuster
5
Spring
4,4 N/mm
Spring preload
10 mm (0,4 in)
Air chamber length
155 mm (5,9 in)
Capacity per fork leg
Fork oil
ca 400 ccm
SAE5
Spring
Spring preload
70/260
23 mm (0,9 in)
10-43D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Rear suspension
Shock absorber
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Front brake
Rear brake
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
Final drive ratio
Chain
Lamps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
KTM 640 DUKE 2000
Central chrome-moly-steel frame
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Multi adjuster 0518U795
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . . . . . driver only = 16, with passenger = 16
fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785
rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in)
standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5
standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3
spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260
Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated
front: 120/70 R 17 58H
rear: 160/60 R 17 69H
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
11 liter (2,9 US gallons), out of this 2,5 liter (0,6 US gallons) reserve
17 : 38
O-ring 5/8 x 1/4"
low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
64,2°
1460 ± 15 mm (57.5 ± 0.6 in)
860 mm (33.9 in)
250 mm (9.9 in)
145 kg (3 lbs)
150 kg (2 lbs)
200 kg (4 lbs)
350 kg (773 lbs)
10-44D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Rear suspension
Shock absorber
Front brake
Rear brake
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
Final drive ratio
Chain
Lamps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
640 DUKE 2000 USA, AUS
Central chrome-moly-steel frame
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Top adjuster 518T780
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . . . . . driver only = 14, with passenger = 14
fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (45 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785
rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in)
standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5
standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3
spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260
Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated
front: 120/70 R 17 58H
rear: 160/60 R 17 69H
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
12 liter (3,2 US gallons), out of this 2,5 liter (0,6 US gallons) reserve
17 : 38
O-ring 5/8 x 1/4"
low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
64,2°
1460 ± 15 mm (57.5 ± 0.6 in)
860 mm (33.9 in)
250 mm (9.9 in)
145 kg (3 lbs)
150 kg (2 lbs)
200 kg (4 lbs)
350 kg (773 lbs)
10-45D
Art.-Nr. 3.206.006 -E
TECHNICAL SPECIFICATIONS – ENGINE
400 SXC USA 2000
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve timing by 1 mm
valve clearence
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
400 SXC
Liquid-cooled single cylinder 4-stroke engine
398 ccm
89 / 64 mm
10,8 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
IO 22° BTDC
EO 60° BBDC
IC 42° ABDC
EC 4° ATDC
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,20 mm Exhaust: 0,20 mm
2 cylinder roller bearing
needle bearing
bronze bushing
cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through Eaton-Oilpump with oil sump
see bellow
1,45 liters (0,38 US gallons)
straight geared spur wheels 30 : 81 teeth
Clutch
Transmission
Gear ratio
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless thyristor ignition with electronic advanced system type SEM
adjustment to max. 38 ° BTDC at 6000 rpm
12V 130W
NGK D8EA
0,6 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
Repair manual KTM LC4
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Connecting rod bearing
Piston cast
Piston rings end gap
Valves
Oil pump
Bypaß valve
Clutch discs
Clutch springs
Transmission shafts
axial play..................................................0,03 - 0,12 mm
run out of crank stud .................................max. 0,08 mm
radial play ..................................................max. 0,05 mm
axial play ...................................................max. 1,00 mm
assembly clearance ...................................max. 0,05 mm
compression rings ......................................max. 0,60 mm
oil scraper ring ...........................................max. 0,80 mm
seat sealing intake......................................max. 1,50 mm
seat sealing exhaust ...................................max. 2,00 mm
run out of valve heads ...............................max. 0,03 mm
valve guides diameter ................................max. 7,05 mm
clearance outer rotor - housing..................max. 0,20 mm
clearance outer rotor - inner rotor..............max. 0,20 mm
minimum spring lenght..........................................25 mm
wear limit organic .................................................2,5 mm
minimum lenght ...........................34,5 mm (new 37 mm)
axial play......................................................0,1 - 0,4 mm
(0,001-0,005 in)
(0,003 in)
(0,002 in)
(0,04 in)
(0,002 in)
(0,023 in)
(0,031 in)
0,059 in)
(0,080 in)
(0,001 in)
(0,277 in)
(0,008 in)
(0,008 in)
(1 in)
(0,1 in)
(1,36 in - new 1,45 in)
(0,004 - 0,016 in)
10-46D
TECHNICAL SPECIFICATIONS - CHASSIS 400 SXC USA
2000
400 SXC
Frame
Central chrome-moly-steel frame
Fork
White Power – EXTREME
Wheel travel front/rear
Rear suspension
295 / 320 mm (11,6 / 12,6 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc Ø 260 mm (10,2 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21 54R
Air pressure offroad
1,0 bar (14 psi)
Air press. road, driver only
1,5 bar (21 psi)
Tyres rear
140/80-18 70R
Air pressure offroad
1,2 bar (17 psi)
Air press. road, driver only
2,0 bar (28 psi)
Fuel tank capacity
9 liter (3 US gallons) of that 1,5 liter (0,4 US gallons) reserve
Final drive ratio
15 : 50
Chain
5/8 x 1/4 "
Steering angle
62,5°
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
940 mm (37 in)
Ground clearance
375 mm (14,8 in)
Dead weight without fuel
121 kg (267 lbs)
STANDARD ADJUSTMENT - FORK
STANDART-ADJUSTMENT - SHOCK ABSORBER
05.18.T7.81
Compression adjuster
10
Rebound adjuster
12
Spring
4,2 N/mm
Spring preload
6 mm (0,24 in)
Air chamber length
130 mm (5,1 in)
Capacity per fork leg
ca 350 ccm
Fork oil
SAE5
NOTE FOR WHITE POWER FORKS:
The damping units in the left and the right fork leg are of different
design. Make sure not to mix them up in case of repair or service works.
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
BST40-225
040599
160
689 X-6
45
6G5
3. from top
2,25 turns
–
–
–
01.18.Q7.82
Compression adjuster
3
Rebound adjuster
4
Spring
63/260
Spring preload
23 mm
10-47D
TECHNICAL SPECIFICATIONS – ENGINE 620 SC, 620 SC SUPERMOTO 2001
Art.-Nr. 3.206.006 -E
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
620
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
609 ccm
101 / 76 mm
10,4 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged aluminium
1 compression ring, 1 taper face ring, 1 oil scraper ring
forced-feed lubrication through Eaton-Oilpump with oil sump
see table
1,6 liters (0,42 US gallons)
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless thyristor ignition with electronic advanced system type KOKUSAN 4K3
adjustment to max. 36 ° BTDC at 5000 rpm
12V 110W
NGK DPR8 EA-9
0,9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F)
decompressor automatic and hand actuated, cold and hot start knob on carburetor
BASIC CARBURETOR SETTING
Repair manual KTM LC4
620 SC,
620 SC SUPERMOTO
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
Throttle valve
Starting jet
Performance restrictor
PHM 40 SD
080600
155
DR 266
45
K 51
3 rd
1,5 turns
40
45
Slide stop 24mm
10-48D
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Connecting rod bearing
Piston forged
Piston rings end gap
Valves
Oil pump
Bypaß valve
Clutch discs
Clutch springs
Transmission shafts
axial play..................................................0,03 - 0,12 mm
run out of crank stud .................................max. 0,04 mm
radial play ..................................................max. 0,05 mm
axial play ...................................................max. 1,00 mm
assembly clearance ...................................max. 0,12 mm
compression rings ......................................max. 0,60 mm
oil scraper ring ...........................................max. 0,80 mm
seat sealing intake......................................max. 1,50 mm
seat sealing exhaust ...................................max. 2,00 mm
run out of valve heads ...............................max. 0,03 mm
valve guides diameter ................................max. 7,05 mm
clearance outer rotor - housing..................max. 0,20 mm
clearance outer rotor - inner rotor..............max. 0,20 mm
minimum spring lenght..........................................25 mm
wear limit organic .................................................2,5 mm
minimum lenght ...........................34,5 mm (new 37 mm)
axial play......................................................0,1 - 0,4 mm
API: SG, SH
TEMPERATURE
–
10W 40
10W 50
+
0°C
32°F
15W 40
15W 50
Engine oil
Use only oil brands, which meet quality requirements
(Shell
Advance
Ultra 4) of API-classes SG or SH (informations on
bottles) or higher.
!
POOR
CAUTION
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY
ENGINE-WEAR.
(0,001-0,005 in)
(0,002 in)
(0,002 in)
(0,04 in)
(0,005 in)
(0,023 in)
(0,031 in)
0,059 in)
(0,080 in)
(0,001 in)
(0,277 in)
(0,008 in)
(0,008 in)
(1 in)
(0,1 in)
(1,36 in - new 1,45 in)
(0,004 - 0,016 in)
10-49D
TECHNICAL SPECIFICATIONS - CHASSIS 620 SC, 620 SC SUPERMOTO 2001
620 SC
620 SC SUPERMOTO
Frame
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 43
Wheel travel front/rear
Rear suspension
295 / 320 mm (11,6 / 12,6 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc, brake caliper floated
Brake Disk
Ø 260 mm (10,2 in)
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21
120/70-17
Air pressure offroad
1,0 bar (14 psi)
–
Air press. road, driver only
1,8 bar (21 psi)
2,0 bar (28 psi)
Tyres rear
140/80-18
160/60-17
Air pressure offroad
1,2 bar (17 psi)
–
Air press. road, driver only
2,0 bar (28 psi)
2,2 bar (32 psi)
Fuel tank capacity
9 liter (2,38 US gallons) of that 2,5 liter (0,66 US gallons) reserve
Final drive ratio
16:40
Chain
62,5°
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
Art.-Nr. 3.206.006 -E
17:38
5/8 x 1/4 " O-Ring
Steering angle
940 mm (37 in)
920 mm (36 in)
Ground clearance
375 mm (14,8 in)
355 mm (14 in)
Dead weight without fuel
122 kg (269 lbs)
123 kg (271 lbs)
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
Repair manual KTM LC4
Ø 320 mm ( 12,6 in)
620 SC
WP 0518V706
14
12
4,2 N/mm
6 mm
150 mm
SAE 5
SC SUPERMOTO
WP 0518V721
14
14
5,0 N/mm
9 mm
130 mm
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload
620 SC
WP 0118V712
3
5
63 / 260
23 mm
SC SUPERMOTO
WP 0118V720
5
7
75 / 260
15 mm
10-50D
TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2001
Type
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Quantity of engine oil
Engine oil
Primary ratio
Clutch
Transmission
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
400 LC4-E
640 LC4-E
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
398 ccm
624,6 ccm
89 / 64 mm
101 / 78 mm
10,8 : 1
11,0 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
Intake: 36 mm
Exhaust: 30 mm
Intake: 0.20 mm Exhaust: 0.20 mm
Intake: 0.15 mm Exhaust: 0.15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
2 Eaton-Oilpumps
see table
2.1 liters including frame
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
contactless DC- CDI ignition with digital advanced system type KOKUSAN
adjustment to max. 38° BTDC at 6000 rpm
12V 200W
NGK DPR8 EA9
0.9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F)
electric starter, kick starter
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Connecting rod bearing
Cylinder 400
Cylinder 640
Piston forged
Piston cast
Piston rings end gap
Valves
Oil pumps
Bypaß valve
Clutch
Camshaft
Transmission shafts
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm
run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm
radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm
oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm
seat sealing intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm
seat sealing exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm
run out of valve heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
valve guides diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm
clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm
Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm)
wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm
diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm
10-51D
GEAR RATIOS
Primary
ratio
Transmission
1st gear
2nd gear
3rd gear
4th gear
5th gear
30:81
Original final
drive ratio
Available chain
drive sprockets
Available final
drive sprockets
15:45
16:42
17:38
17:42
15 t
16 t for chain
17 t 5/8 x 1/4"
38
40
42
45
48
14:35
15:24
18:21
20:19
22:18
t
t for chain
t 5/8 x 1/4"
t
t
Engine oil
Use only oil brands, which meet quality requirements (Shell Advance
Ultra 4) of API-classes SG or SH (informations on bottles) or higher.
API: SG, SH
TEMPERATURE
–
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
10W 40
10W 50
0°C
32°F
+
!
POOR
CAUTION
15W 40
15W 50
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
400 LC4-E
400 LC4-E
25 kW
31 kW
400 LC4-E
USA
PHM 38 ND
100197
130
AR 264
50
K 23
2. from top
1.5 turns
50/1
45(50,55)
slide stop 51mm
PHM 38 ND
100197
130
AR 264
50
K 23
2. from top
1,5 turns
50/1
45(50,55)
–
BST40-225
090298
142,5
689 X-6
45
6G5
3. from top
2,25 turns
–
–
–
640 LC4-E, Adventure
640 LC4-E, Adventure
640 Duke
25 kW
36 kW
40 kW
BST40-225
080298
142,5
689 X-6
45
6G5
3. from top
2,25
–
–
slide stop 17mm
BST40-225
090298
142,5
689 X-6
45
6G5
3. from top
2,25
–
–
–
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Throttle valve
Starting jet
Performance restrictor
!
OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR.
BST40-225
100299
145
689 X-6
45
6G5
3. from top
2,25
–
–
–
10-52D
TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2001
400 LC4-E
640 LC4-E
640 LC4-E SUPERMOTO
Frame
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 43
Wheel travel front/rear
270 / 300 mm (10,6 / 11,8 in)
Rear suspension
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc, brake caliper floated
Brake Disk front
Ø 300 mm (11,8 in)
Rear brake
Ø 320 mm ( 12,6 in)
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
90/90-21
120/70-17
Air press. road, driver only
Tyres front
1,5 bar (21 psi)
2,0 bar (28 psi)
Air press. road, with passenger
2,0 bar (28 psi)
2,2 bar (31 psi)
140/80-18
160/60-17
Air press. road, driver only
2,0 bar (28 psi)
2,2 bar (31 psi)
Air press. road, with passenger
2,2 bar (31 psi)
2,4 bar (34 psi)
Tyres rear
Fuel tank capacity
11 liter (2,9 US gallons) / 18 liter (4,75 US gallons)
2,5 liter (0,66 US gallons) reserve
Final drive ratio
15:45
16:42
17:42
Chain
Lamps
5/8 x 1/4 " O-Ring
head light . . . . . . . . . . . . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)
parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illumination . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
Battery
12V 8Ah
Steering angle
62,5°
Wheel base
63°
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
955 mm (37,6 in)
935 mm (36,8 in)
Ground clearance
355 mm (14 in)
335 mm (13,2 in)
Dead weight without fuel
136 kg (300 lbs)
137 kg (302 lbs)
Max. permissable front axe load
211 kg (466 lbs)
Max. permissable rear axe load
335 kg (740 lbs)
Max. permissable laden weigth
350 kg (773 lbs)
STANDARD ADJUSTMENT - FORK
400/640 LC4-E
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
WP 0518V707
20
12
4,4 N/mm
6 mm
150 mm
SAE 5
640 LC4-E
SUPERMOTO
WP 0518V721
14
14
5,0 N/mm
9 mm
130 mm
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
400/640 LC4-E
Compression adjuster
Rebound adjuster
Spring
Spring preload
WP 0118V710
6
7
66 / 260
27 mm
640 LC4-E
SUPERMOTO
WP 0118V720
5
7
75 / 260
15 mm
10-53D
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE
2001
640 LC4 Adventure
Frame
Central chrome-moly-steel frame
Fork
WP USD
Wheel travel front/rear
Rear suspension
275/300 mm (10,5/12 in)
Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc Ø 320 mm (11,8 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21 Enduro3
Air pressure offroad
1,8 bar (21 psi)
Air press. road, driver only
2,0 bar (29 psi)
Tyres rear
140/80-18 Enduro3
Air press. road, driver only
2,0 bar (29 psi)
Air press. road, with passenger
2,2 bar (32 psi)
Fuel tank capacity
28 liter (7,4 US gallons) of that 3,5 liter (1 US gallons) reserve
Final drive ratio
16 : 42
Chain
5/8 x 1/4 " O-Ring
Battery
maintenance-free battery
Steering angle
Art.-Nr. 3.206.006 -E
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
955 mm (37,7 in)
Ground clearance
355 mm (14,2 in)
Dead weight without fuel
154 kg (340 lbs)
Max. permissible front axle load
150 kg (331 lbs)
Max. permissible rear axle load
230 kg (507 lbs)
Max. permissible laden weight
380 kg (839 lbs)
STANDARD ADJUSTMENT - FORK
STANDARD-ADJUSTMENT - SHOCK ABSORBER
14.18.V704
14
Compression adjuster
Rebound adjuster
14
Rebound adjuster
Spring preload
Air chamber length
Repair manual KTM LC4
01.18.V709
Compression adjuster
Spring
Capacity per fork leg
Fork oil
12V 8Ah
62,5°
4,4 N/mm
4 mm
120 mm
ca 420 ccm
SAE 5
Spring
Spring preload
3
5
66/260
27 mm (0,9 in)
10-54D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Rear suspension
Shock absorber
Front brake
Rear brake
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
Final drive ratio
Chain
Lamps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
KTM 640 DUKE 2001
Central chrome-moly-steel frame
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Multi adjuster 0518U795
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . . . . . driver only = 16, with passenger = 16
fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785
rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in)
standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5
standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3
spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260
Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated
front: 120/70 R 17 58H
rear: 160/60 R 17 69H
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
11 liter (2,9 US gallons), out of this 2,5 liter (0,6 US gallons) reserve
17 : 38
O-ring 5/8 x 1/4"
low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
64,2°
1460 ± 15 mm (57.5 ± 0.6 in)
860 mm (33.9 in)
250 mm (9.9 in)
145 kg (3 lbs)
150 kg (2 lbs)
200 kg (4 lbs)
350 kg (773 lbs)
10-55D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Rear suspension
Shock absorber
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Front brake
Rear brake
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
Final drive ratio
Chain
Lamps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
640 DUKE 2001 USA, AUS
Central chrome-moly-steel frame
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Top adjuster 518T780
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . . . . . driver only = 14, with passenger = 14
fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (45 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785
rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in)
standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5
standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3
spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260
Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated
front: 120/70 R 17 58H
rear: 160/60 R 17 69H
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
12 liter (3,2 US gallons), out of this 2,5 liter (0,6 US gallons) reserve
17 : 38
O-ring 5/8 x 1/4"
low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
64,2°
1460 ± 15 mm (57.5 ± 0.6 in)
860 mm (33.9 in)
250 mm (9.9 in)
145 kg (3 lbs)
150 kg (2 lbs)
200 kg (4 lbs)
350 kg (773 lbs)
10-56D
TECHNICAL SPECIFICATIONS – ENGINE 625 SC, 625 SC SUPERMOTO 2002
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
625 LC4
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
625 ccm
101 / 78 mm
11,0 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
Intake: 36 mm
Exhaust: 30 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
two oilpumps
10W-40 (Shell Advance Ultra 4)
1,6 liters (0,42 US gallons)
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless DC-CDI ignition with digital advanced system type KOKUSAN 4K-3C
adjustment to max. 38 ° BTDC at 6000 rpm
12V 150 W
NGK DPR8 EA-9
0,9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F)
Kickstarter, cold start knob on carburetor
BASIC CARBURETOR SETTING
625 SC,
625 SC SUPERMOTO
Carburetor
Carburetor setting number
Main jet
Needle jet
Idling jet
Main air jet
Idling air jet
Needle position from top
Throttle valve
Starting jet
Performance restrictor
Stop pump membrane
Keihin FCR41
140501
180
OBDVT
45
200
100
5th
15
85
Slide stop 23mm
3,2mm
10-57D
TECHNICAL SPECIFICATIONS - CHASSIS 625 SC, 625 SC SUPERMOTO 2002
625 SC
Art.-Nr. 3.206.006 -E
Frame
Fork
Wheel travel front/rear
Rear suspension
Front brake
Front brake disc
Rear brake
Tyres front
Air press. offroad
Air press. road
Tyres rear
Air press offroad
Air press. road
Fuel tank capacity
Final drive ratio
Chain
Bulps
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
625 SC SUPERMOTO
Central chrome-moly-steel frame
White Power 4357 MXMA
295 / 320 mm (11,8 / 12,8 in)
270 / 320 (10,8 / 12.8 in)
Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing
Disc brake with carbon-steel brake disc, brake caliper floated
Ø 260 mm (10,4 in)
Ø 320 mm (12.8 in)
Disc brake with carbon-steel brake disc 220 mm (8.8 in), brake caliper floated
90/90-21
120/70-17
1,0 bar (14 psi)
1,8 bar (26 psi)
2,0 bar (29 psi)
140/80-18
160/60-17
1,2 bar (17 psi)
2,0 bar (29 psi)
2,2 bar (32 psi)
9 liter (2,3 US gallons), 1.5 liter (0,4 US gallons) reserve
16:40 (15:50) t
17:38t
X – Ring 5/8 x 1/4"
headlight . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)
parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d)
brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination . . . 12V 5W (socket W2,1x9,5 d)
62,5 °
63°
1510 ± 10 mm (59.4 ± 0.4 in)
950 mm (38 in)
920 mm (36.8 in)
340 mm (13,6 in)
300 mm (12 in)
122 kg (269 lbs)
123 kg (271 Ibs)
Repair manual KTM LC4
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
625 SC
625 SC SUPERMOTO
WP 0518W712
WP 0518W722
20
14
12
14
4,2 N/mm
5,0 N/mm
5 mm
9 mm
140 mm
130 mm
SAE 5
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload
625 SC
WP 0118W714
3
5
63 / 260
23 mm
625 SC SUPERMOTO
WP 0118W721
5
7
75 / 260
15 mm
10-58D
TECHNICAL DATA – ENGINE 640 LC4
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
640 LC4
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
624,6 ccm
101 / 78 mm
11 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
249/1
Intake: 36 mm
Exhaust: 30 mm
0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
two oilpumps
10W-40 (Shell Advance Ultra 4)
appr. 2,1 liters including frame
straight geared spur wheels 30 : 81 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
contactless DC-CDI ignition with digital advanced system type KOKUSAN 4K-2
adjustment to max. 38° BTDC at 6000 rpm
12V 200W
NGK DPR8 EA9
0,9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
electric starter and kickstarter
BASIC CARBURETOR SETTING
Type
Carb.-setting number
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
2002
640 LC4, SUPERMOTO
640 LC4 ADVENTURE
640 DUKE
40 kW
BST40-225
090298
142,5
689 X-6
45
6G5
3.
2,25
BST40-225
100299
145
689 X-6
45
6G5
3.
2,25
10-59D
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2002
640 LC4
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Frame
Fork
Wheel travel front/rear
Rear suspension
Front brake
Front brake disc
Rear brake
Tyres front
Air press. road, driver only
Air press. road with passenger
Tyres rear
Air press. road, driver only
Air press. road with passenger
Fuel tank capacity
Final drive ratio
Chain
Bulps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
640 LC4 Supermoto
Central chrome-moly-steel frame
White Power – Up Side Down 4357 MXMA
270 / 300 mm (10,6 / 11.8 in)
Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing
Disc brake with carbon-steel brake disc, brake caliper floated
Ø 300 mm (11.8 in)
Ø 320 mm (12.6 in)
Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated
90/90-21
120/70-17
1.8 bar (26 psi)
2.0 bar (29 psi)
2.0 bar (29 psi)
2.2 bar (31 psi)
140/80-18
160/60-17
2.0 bar (29 psi)
2.2 bar (31 psi)
2.2 bar (31 psi)
2.4 bar (34 psi)
11 or 18 liter (2.9 or 4.8 US gallons), 2.5 liter (0,6 US gallons) reserve
16:42t
17:42t
X – Ring 5/8 x 1/4"
headlight . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)
parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
instrument lights . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d)
brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination . . . 12V 5W (socket W2,1x9,5 d)
maintenance-free battery 12V 8Ah
62,5 °
63°
1510 ± 10 mm (59.4 ± 0.4 in)
940 mm (37.6 in)
910 mm (36.4 in)
355 mm (14.0 in)
335 mm (13.2 in)
136kg (300 lbs)
137 kg (302 Ibs)
211 kg (465 lbs)
335 kg (740 lbs)
350 kg (773 lbs)
STANDARD ADJUSTMENT - FORK
640 LC4
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
WP 0518W714
20
12
4,2 N/mm
6 mm (0,24in)
150 mm (5,9in)
SAE 5
640 LC4
SUPERMOTO
WP 0518W722
14
14
5,0 N/mm
9 mm (0,36in)
130 mm (5,1in)
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
640 LC4
Compression adjuster
Rebound adjuster
Spring
Spring preload
WP 0118W724
3
7
66 / 260
23,5 mm(0,94in)
640 LC4
SUPERMOTO
WP 0118W721
5
7
75 / 260
15 mm(0,6in)
10-60D
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE
Frame
Fork
Wheel travel front/rear
Rear suspension
bearing
Front brake
Rear brake
Tyres front
Air pressure offroad
Air press. road, driver only
Tyres rear
Air press. road, driver only
Air press. road, with passenger
Fuel tank capacity
Final drive ratio
Chain
Lampenbestückung
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
640 LC4 Adventure
Central chrome-moly-steel frame
WP USD MXMA 4860
275/300 mm (10,5/12 in)
Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with need
Disc brake with carbon-steel brake disc Ø 320 mm (11,8 in), brake caliper floated
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
90/90-21 Enduro3
1,8 bar (21 psi)
2,0 bar (29 psi)
140/80-18 Enduro3
2,0 bar (29 psi)
2,2 bar (32 psi)
28 liter (7,4 US gallons) of that 2 liter (0,5 US gallons) reserve
16 : 42
5/8 x 1/4 "X-Ring
head light . . . . . . . . . . . . . . . . . . . . . .H1 12V 55W (Sockel P14,5S)
parking light . . . . . . . . . . . . . . . . . . . .12V 2W (Sockel Ba9s)
brake- rear light . . . . . . . . . . . . . . . . .12V 21/5W (Sockel BaY15d)
flasher light . . . . . . . . . . . . . . . . . . . . .12V 10W (Sockel Ba15s)
license plate illintion . . . . . . . . . . . . . .12V 5W (Sockel W2,1x9,5d)
maintenance-free battery 12V 8Ah
62,5°
1510 ± 10 mm (59,4 ± 0,4 in)
955 mm (37,7 in)
355 mm (14,2 in)
154 kg (340 lbs)
150 kg (331 lbs)
230 kg (507 lbs)
380 kg (839 lbs)
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Capacity per fork leg
Fork oil
2002
WP 4860 MXMA
1418W711
14
14
4,4 N/mm
4 mm
120 mm
approx. 420 ccm
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload
WP BAVP3612
0118W715
6
7
70/260
27 mm (0,9 in)
10-61D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Rear suspension
Shock absorber
0118W71
640 DUKE II
2002
Central chrome-moly-steel frame
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 4357 ROMA 0518716
wheel travel . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in)
standard adjustment compression. . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound. . . . . . . . . . driver only = 16, with passenger = 16
fork leg projection upper fork bridge . . . . 3 mm (0,12 in)
oil capacity per fork leg . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . 100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 4681
rear wheel travel . . . . . . . . . . . . .
standard adjustment compression.
standard adjustment rebound. . . .
spring preload . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
170 mm (6.7 in)
driver only = 3, with passenger = 5
driver only = 5, with passenger = 3
driver only = 23 mm (0.9 in),with passenger = 28
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
mm (1.1 in)
Front brake
Rear brake
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
Final drive ratio
Chain
Lamps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
spring type . . . . . . . . . . . . . . . . . . . . . . . 70 - 260
Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated
front: 120/70 R 17 58H
rear: 160/60 R 17 69H
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
11 liter (2,9 US gallons), out of this 2,5 liter (0,6 US gallons) reserve
17 : 38
X-ring 5/8 x 1/4"
low beam . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
64,2°
1460 ± 15 mm (57.5 ± 0.6 in)
880 mm (34,7 in)
250 mm (9.9 in)
145 kg (3 lbs)
150 kg (2 lbs)
200 kg (4 lbs)
350 kg (773 lbs)
10-62D
TECHNICAL SPECIFICATIONS – ENGINE 625 SXC 2003
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
625 SXC
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
625 ccm
101 / 78 mm
11,5 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
584-V03/1
Intake: 36 mm
Exhaust: 32 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
two Eaton-oilpumps
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
1,6 liters (0,42 US gallons)
straight geared spur wheels 31 : 79 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless DC-CDI ignition with digital advanced system type KOKUSAN
adjustment to max. 38 ° BTDC at 6000 rpm
12V 200W
NGK DCPR8 E
0,9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F)
kick - electric starter
BASIC CARBURETOR SETTING
BASIC CARBURATOR SETTING
625 SXC
USA
625 SXC
Type
Carburator-setting number
Main jet
Jet needle
Idling jet
Main air jet
Idling air jet
Needle position
Starting jet
Mixture control screw open
Slide
Performance restrictor
Stop pump membrane
Hot start device
Keihin FCR-MX 41
4138A
165
OBDVT
42
200
100
5. rd from top
85
2
15
Slide stop
858 / 2,15 mm
3,8 mm
Type
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
Mikuni BST40-266
152,5
X-6 689
45
6G5
3. from top
2,25
10-63D
TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 2003
Art.-Nr. 3.206.006 -E
Frame
Fork
Wheel travel front/rear
Rear suspension
Front brake
Front brake disc
Rear brake
Tyres front
Air press. offroad
Air press. road
Tyres rear
Air press offroad
Air press. road
Fuel tank capacity
Final drive ratio
Chain
Bulps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
625 SXC
Central chrome-moly-steel frame
White Power 4357 MXMA
295 / 320 mm (11,8 / 12,8 in)
Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing
Disc brake with carbon-steel brake disc, brake caliper floated
Ø 260 mm (10,4 in)
Disc brake with carbon-steel brake disc 220 mm (8.8 in), brake caliper floated
90/90-21
1,0 bar (14 psi)
1,8 bar (26 psi)
140/80-18
1,2 bar (17 psi)
2,0 bar (29 psi)
9 liter (2,3 US gallons), 2.5 liter (0,6 US gallons) reserve
16:40 ( USA 15:50) t
X – Ring 5/8 x 1/4"
headlight . . . . . . . . . . . . . HS1 12V 35/35W (socket PX43t)
parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d)
brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination . . . 12V 5W (socket W2,1x9,5 d)
maintenance-free battery 12V 8,6 Ah
62,5 °
1510 ± 10 mm (59.4 ± 0.4 in)
980 mm (39,2 in)
360 mm (14,4 in)
132 kg (291 lbs)
Repair manual KTM LC4
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
625 SXC
WP 0518X729
20
12
4,2 N/mm
5 mm
140 mm
SAE 5
STANDARD-ADJUSTMENT-SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload
625 SXC
WP 0118X725
3
5
63 / 260
23 mm
10-64D
TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
640 LC4
Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter
625 ccm
101 / 78 mm
11.5 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
584-V03/1
Intake: 36 mm
Exhaust: 32 mm
0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged/cast aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
two Eaton-oilpumps
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
appr. 2,1 liters including frame
straight geared spur wheels 31 : 79 teeth
multi disc clutch in oil bath, hydraulically operated
5-speed claw shifted
1st
14:35
2nd
15:24
3rd
18:21
4th
20:19
5th
22:18
contactless DC-CDI ignition with digital advanced system type KOKUSAN 4K5
adjustment to max. 38° BTDC at 6000 rpm
12V 200W
NGK DCPR 8 E
0,9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F)
electric starter and kickstarter
BASIC CARBURETOR SETTING
BASIC CARBURETOR SETTING
640 LC4
640 LC4 Supermoto
Type
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
BST40-266
152,5
X-6 689
45
6G5
3. from top
2,25
BASIC CARBURETOR SETTING
640 DUKE
40 kW
Carburetor
Main jet
Needle jet
Idling jet
Jet needle
Needle position from top
Mixture.adju. screw open
2003
BST40-258
145
689 X-6
45
6G5
3 rd
2.25 turn
640 LC4 Adventure
Type
Main jet
Needle jet
Idling jet
Jet needle
Needle clip pos. f. top
Mixt. adj. screw open
BST40-266
152,5
X-6 689
45
6G5
3. from top
2,25
10-65D
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2003
Art.-Nr. 3.206.006 -E
640 LC4
640 LC4 Supermoto
Frame
Central chrome-moly-steel frame
Fork
White Power – Up Side Down 4357 MXMA
White Power – Up Side Down 4860 MXMA
Wheel travel front/rear
270 / 300 mm (10,6 / 11.8 in)
265 / 310 mm (10,4 / 12,2 in)
Rear suspension
Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing
Front brake
Disc brake with carbon-steel brake disc,
Disc brake with carbon-steel brake disc,
2-piston brake caliper floated
4-piston brake caliper
Front brake disc
Ø 300 mm (11.8 in)
Ø 320 mm (12.6 in)
Rear brake
Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated
Tyres front
90/90-21
120/70-17
Air press. road, driver only
1.8 bar (26 psi)
2.0 bar (29 psi)
Air press. road with passenger
2.0 bar (29 psi)
2.2 bar (31 psi)
Tyres rear
130/80-18
160/60-17
Air press. road, driver only
2.0 bar (29 psi)
2.2 bar (31 psi)
Air press. road with passenger
2.2 bar (31 psi)
2.4 bar (34 psi)
Fuel tank capacity
11 liter (2.9 US gallons), 2.5 liter (0.6 US gallons) reserve
Final drive ratio
16:42t
17:42t
Chain
X – Ring 5/8 x 1/4"
Bulps
headlight . . . . . . . . . . . . . H4 12V 60/55W (socket P43t)
parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
instrument lights . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d)
brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination . . . 12V 5W (socket W2,1x9,5 d)
Battery
maintenance-free battery 12V 8,6Ah
Steering angle
62°
63°
Wheel base
1510 ± 10 mm (59.4 ± 0.4 in)
Seat high
925 mm (36.4 in)
910 mm (35.9 in)
Ground clearance
310 mm (12.2 in)
290 mm (11.4 in)
Dead weight without fuel
149kg (329 lbs)
149 kg (329 Ibs)
Max. permissible front axle load
150 kg (331 lbs)
Max. permissible rear axle load
230 kg (508 lbs)
Max. permissible laden weight
350 kg (773 lbs)
STANDARD ADJUSTMENT - FORK
Repair manual KTM LC4
640 LC4
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
WP 0518X730
20
12
4,2 N/mm
6 mm (0.24in)
150 mm (5,9in)
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
640 LC4
SUPERMOTO
WP 0518X738
20
15
4,4 N/mm
28 mm (1.1in)
110 mm (4.3in)
SAE 5
640 LC4
Compression adjuster
Rebound adjuster
Spring
Spring preload
WP 0118X729
3
7
66 / 260
23,5 mm(0,93in)
640 LC4
SUPERMOTO
WP 0118X730
4
8
70 / 260
16 mm(0,63in)
10-66D
TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE
2003
640 LC4 Adventure
Frame
Central chrome-moly-steel frame
Fork
WP USD MXMA 4860
Wheel travel front/rear
Rear suspension
275/300 mm (10,5/12 in)
Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with needle bearing
Front brake
Disc brake with carbon-steel brake disc Ø 320 mm (11,8 in), brake caliper floated
Rear brake
Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated
Tyres front
90/90-21 Enduro3
Air pressure offroad
1,8 bar (21 psi)
Air press. road, driver only
2,0 bar (29 psi)
Tyres rear
140/80-18 Enduro3
Air press. road, driver only
2,0 bar (29 psi)
Air press. road, with passenger
2,2 bar (32 psi)
Fuel tank capacity
28 liter (7,4 US gallons) of that 3,5 liter (0,9 US gallons) reserve
Final drive ratio
16 : 42
Chain
5/8 x 1/4 "X-Ring
Bulbs
head light . . . . . . . . . . . . . . . . . . . . . .H1 12V 55W (Sockel P14,5S)
parking light . . . . . . . . . . . . . . . . . . . .12V 2W (Sockel Ba9s)
brake- rear light . . . . . . . . . . . . . . . . .12V 21/5W (Sockel BaY15d)
flasher light . . . . . . . . . . . . . . . . . . . . .12V 10W (Sockel Ba15s)
license plate illintion . . . . . . . . . . . . . .12V 5W (Sockel W2,1x9,5d)
Battery
maintenance-free battery
Steering angle
62,5°
Wheel base
1510 ± 10 mm (59,4 ± 0,4 in)
Seat high
945 mm (37,2 in)
Ground clearance
315 mm (12,4 in)
Dead weight without fuel
158 kg (340 lbs)
Max. permissible front axle load
150 kg (331 lbs)
Max. permissible rear axle load
230 kg (507 lbs)
Max. permissible laden weight
380 kg (839 lbs)
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Capacity per fork leg
Fork oil
12V 8Ah
WP 4860 MXMA
1418X728
14
14
4,4 N/mm
4 mm
120 mm
ca 420 ccm
SAE 5
STANDARD-ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload
WP BAVP3612
0118X726
6
7
70/260
27 mm (0,9 in)
10-67D
TECHNICAL SPECIFICATIONS - CHASSIS
Frame
Fork
Rear suspension
Shock absorber
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Front brake
Rear brake
Tyres
Air pressure rider only
Air pressure with passenger
Fuel tank capacity
Final drive ratio
Chain
Lamps
Battery
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
Max. permissible front axle load
Max. permissible rear axle load
Max. permissible laden weight
640 DUKE II
2003
Central chrome-moly-steel frame
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 4357 ROMA 0518X732
wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5.5 in)
standard adjustment compression . . . . . . . . . . . driver only = 14, with passenger = 14
standard adjustment rebound . . . . . . . . . . . . . . driver only = 16, with passenger = 16
fork leg projection upper fork bridge . . . . . . . . . 3 mm (0.12 in)
oil capacity per fork leg . . . . . . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5
air chamber lenght . . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in)
WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 4681 0118X728
rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in)
standard adjustment compression . . . . . . . . . . . driver only = 3, with passenger = 5
standard adjustment rebound . . . . . . . . . . . . . . driver only = 5, with passenger = 3
spring preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in)
spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260
Disc brake with carbon-steel floated brake disc Ø 320 mm (12.6 in) and 4-piston brake caliper
Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in) and single-piston brake caliper floated
front: 120/70 R 17 58H
rear: 160/60 R 17 69H
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
11 liters (2.9 US gallons), out of this 2.5 liters (0.6 US gallons) reserve
16 : 38
X-ring 5/8 x 1/4"
low beam . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
high beam . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d)
parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d)
indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d)
stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d)
flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s)
maintenance-free battery 12V 8Ah
63.5°
1460 ± 15 mm (57.5 ± 0.6 in)
900 mm (35.5 in)
270 mm (10.6 in)
149 kg (329 lbs)
150 kg (331 lbs)
200 kg (441 lbs)
350 kg (773 lbs)
10-68D
TECHNICAL SPECIFICATIONS – ENGINE 660 SMC 2003
Engine
Design
Displacement
Bore / Stroke
Ratio
Fuel
Valve timing
Camshaft
Valve diameter
Valve clearence cold
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
Piston rings
Engine lubrication
Engine oil
Engine oil quantity
Primary ratio
Clutch
Transmission
Gear ratio
Ignition system
Ignition timing
Generator
Spark plug
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
660 SMC
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
653 ccm
102 / 80 mm
11,5 : 1
unleaded premium gasoline with a least RON 95
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
586-V039
Intake: 36 mm
Exhaust: 32 mm
Intake: 0,15 mm Exhaust: 0,15 mm
2 cylinder roller bearing
needle bearing
bronze bushing
forged aluminium alloy
1 compression ring, 1 taper face ring, 1 oil scraper ring
two Eaton-oilpumps
SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T)
1,6 liters (0,42 US gallons)
straight geared spur wheels 31 : 79 teeth
multi disc clutch in oil bath
5-speed claw shifted
1st 14:35
2nd 15:24
3rd 18:21
4th 20:19
5th 22:18
contactless DC-CDI ignition with digital advanced system type KOKUSAN
adjustment to max. 38 ° BTDC at 6000 rpm
12V 200W
NGK DCPR8 E
0,9 mm
liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump
at least –25°C (–13°F)
kickstarter
BASIC CARBURATOR SETTING
660 SMC
Type
Carburator-setting number
Main jet
Jet needle
Idling jet
Main air jet
Idling air jet
Needle position
Starting jet
Mixture control screw open
Slide
Performance restrictor
Stop pump membrane
Hot start device
Keihin FCR-MX 41
4138A
165
OBDVT
42
200
100
5. rd from top
85
2
15
Slide stop
858 / 2,15 mm
3,8 mm
10-69D
TECHNICAL SPECIFICATIONS - CHASSIS 660 SMC 2003
Art.-Nr. 3.206.006 -E
Frame
Fork
Wheel travel front/rear
Rear suspension
Front brake
Front brake disc
Rear brake
Tyres front
Air press.
Tyres rear
Air press.
Fuel tank capacity
Final drive ratio
Chain
Bulps
Steering angle
Wheel base
Seat high
Ground clearance
Dead weight without fuel
660 SMC
Central chrome-moly-steel frame
White Power 4860 MXMA
265 / 310 mm (10,6 / 12,4 in)
Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing
Disc brake with carbon-steel brake disc, and 4 piston brake caliper
Ø 320 mm (12,8 in)
Disc brake with carbon-steel brake disc 220 mm (8.8 in), brake caliper floated
120/70-17
2 bar (29 psi)
160/60-17
2,2 bar (31 psi)
9 liter (2,3 US gallons), 2.5 liter (0,6 US gallons) reserve
16:38
X – Ring 5/8 x 1/4"
headlight . . . . . . . . . . . . . HS1 12V 35/35W (socket PX43t)
parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d)
indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d)
brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d)
flasher light . . . . . . . . . . . 12V 10W (socket Ba15s)
license plate illmination . . . 12V 5W (socket W2,1x9,5 d)
63 °
1510 ± 10 mm (59.4 ± 0.4 in)
910 mm (36,4 in)
290 mm (11,6 in)
131 kg (289 lbs)
Repair manual KTM LC4
STANDARD ADJUSTMENT - FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil
660 SMC
WP 1418X738
20
15
4,4 N/mm
28 mm
110 mm
SAE 5
STANDARD-ADJUSTMENT-SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload
660 SMC
WP 0118X730
4
8
70 / 260
22 mm
10-70D
TIGHTENING TORQUE - ENGINE
Hexagon nut at primary gear
Collar nut flywheel (LC4, ADVENTURE, DUKE)
Collar nut flywheel (SC, SXC)
Hexagon nut for inner clutch hub
Collar bolt clutch springs
Kickstarter stop bolt
Allen head bolt freewheel hub (E-STARTER)
Allen head bolts oil pumps
Collar bolts oil pumps (from modell 2003 on)
Hexagon bolt camshaft gear
Allen head bolts cylinder head top section
Allen head bolts cylinder head top section
Bolts cylinder head top section (from model 2003 on)
Bolts cylinder head top section (from model 2003 on)
Cylinder head to cylinder
Cylinder head to cylinder
Cylinder head to cylinder (from model 2003 on)
Cylinder head bolts
Collar nuts at cylinder base
Plug at cylinder head (SC)
Hexagon bolt chain sprocket 8.8
Hexagon bolt chain sprocket 12.9
Nut chain sprocket
Oil drain plug
Magnetic plug
Plug bypass valve
Banjo bolts oil lines
Banjo bolts oil lines
Jet screw clutch cover
Plug timing-chain tensioner
Timing-chain tensioner to cylinder
Timing-chain tensioner to cylinder (from model 2003 on)
Timing-chain guide to cylinder
Hexagon bolt timing-chain guide
Tension guide
Timing-chain securing guide
Allen head bolt timing-chain securing guide (from model 2003 on)
Counternuts valve adjusting screws
Crankshaft locking bolt
Spark plug
Engine mounting bolt
Engine mounting bolt
Retaining plate for main shaft bearing
Retaining plate for main shaft bearing (from model 2003 on)
Shift mechanism support, securing device for bearing
Shift mechanism support
Shift mechanism support (from model 2003 on)
Shift drum locating
Engine housing, clutch cover, ignition cover
Water pump cover
Bolts of impuls generator
Stator (SC)
Stator (E-Start)
Kick starter
Shifting lever
Oil filter cover
Microfilter cover (SC)
Starter flange, starter cover
AH bolt for slave cylinder
Starter
Valve cover
Exhaust flange
AH screw for decompression shaft lever
Retaining shim for ignition (SC)
Other bolts, engine
M20x1,5
Loctite 243 + 170 Nm
M16x1,25 links
80° C + 150 Nm
M12x1 left
60 Nm
M18x1,5
Loctite 243 + 100 Nm
M6
10 Nm
M12x1,5
50 Nm
M6x12/M6x12,5
Loctite 648 + 12/16 Nm
M6
Loctite 243 + 8 Nm
M6
Loctite 243 + 10 Nm
M10
Loctite 243 + 35 Nm
M6x25/M6x35/M6x65/M6x70 (8.8)
8 Nm
M6x50/M6x55 (12.9)
15 Nm
M6 (8.8)
10 Nm
M7 (12.9)
15 Nm
M8
25 Nm
M6
8 Nm
M6
10 Nm
M10
50 Nm
M10
40 Nm
M10
20 Nm
M10
Loctite 243 + 40 Nm
M10
Loctite 243 + 60 Nm
M20x1,5
60 Nm
M22x1,5
30 Nm
M12x1,5
20 Nm
M12x1,5
20 Nm
M8x1
10 Nm
M10x1
15 Nm
M8
10 Nm
M12x1,5
20 Nm
M6
Loctite 243 + 8 Nm
M6
10 Nm
M12x1,25
Loctite 243 + 8 Nm
M6
Loctite 243 + 10 Nm
M8
Loctite 243 + 15 Nm
M6
8 Nm
M6
Loctite 243 + 10 Nm
M7x0,75
16 Nm
M8
25 Nm
M12x1,25
20 Nm
M8
40 Nm
M10
70 Nm
M6
Loctite 648 + 8 Nm
M6
Loctite 648 + 10 Nm
M5
Loctite 243 + 6 Nm
M6
Loctite 243 + 8 Nm
M6
Loctite 243 + 10 Nm
M6
Loctite 243 + 8 Nm
M6
10 Nm
M6
10 Nm
M5
Loctite 243 + 6 Nm
M6
Loctite 243 + 8 Nm
M5
Loctite 243 + 6 Nm
M8
25 Nm
M6
Loctite 243 + 10 Nm
M6
10 Nm
M5
6 Nm
M6
10 Nm
M6
10 Nm
M6
10 Nm
M6
10 Nm
M6
10 Nm
M6
Loctite 243 + 10 Nm
M5
Loctite 243 + 6 Nm
M5
6 Nm
M6
10 Nm
10-71D
TIGHTENING TORQUE - CHASSIS
Art.-Nr. 3.206.006 -E
Collar nut front axle
M16x1,5, M17
40 Nm
Collar nut front axle (400 SXC)
M10
40 Nm
Collar nut front axle
M24x1,5
40 Nm
Collar nut rear axle
M20x1,5
80 Nm
Shock absorber top
M10
45 Nm
Shock absorber bottom
M10
Collar bolts brake disk front
M6
Loctite 243 + 10 Nm
Collar bolts brake disk front
M6
Loctite 243 + 10 Nm
Bolts brake caliper front
M8
Loctite 243 + 25 Nm
45 Nm
Bolts brake caliper front (LC4 Supermoto)
M10
Loctite 243 + 40 Nm
Allen head bolts brake caliper front (DUKE)
M10x1,25
Loctite 243 + 45 Nm
Allen head bolt brake caliper support rear (DUKE)
M10
40 Nm
Allen head bolts brake caliper front (660 SMC)
M10
60 Nm
Bearing bolt linkage arm/frame
M12
Collar nuts rocker arm bolts
M14x1,5
Engine mounting bolt
M10
Ball joint for push rod
M8
Loctite 243 + 25 Nm
Sprocket bolts with nuts
M8
Loctite 243 + 35 Nm
Collar nut swingarm bolt
M14x1,5
60 Nm
100 Nm
45 Nm
100 Nm
Clamping bolts top triple clamp (USD 43)
M8
20 Nm
Clamping bolts top triple clamp (EXTREME)
M8
15 Nm
Clamping bolts top triple clamp (USD 48)
M8
20 Nm
Clamping bolts bottom triple clamp (USD 43)
M8
15 Nm
Clamping bolts bottom triple clamp (EXTREME)
M8
20 Nm
Clamping bolts bottom triple clamp (USD 48)
M8
15 Nm
Clamp bolts for front wheel axle clamp
M8
10 Nm
Collar nut for eccentric chain adjuster (DUKE)
M10
40 Nm
Bolts, handlebar clamp
M8
Loctite 243 + 20 Nm
Allen head bolts handle bar support, damped
M10
Loctite 243 + 20 Nm
Allen head bolts handle bar support, not damped (SC, SC-SM, SXC)
M10
Loctite 243 + 40 Nm
Rim lock
M8
5 Nm
Clamping of steering stemm
M8
20 Nm
Subframe
M8
Loctite 243 + 35 Nm
Spoke nipple
M4
4 Nm
Repair manual KTM LC4
(LC4, LC4-SM, SMC, ADVENTURE, DUKE)
Blocking bolt of adjusting ring for spring preload
M6
8 Nm
Other bolts on chassis
M6
10 Nm
M8
25 Nm
M10
45 Nm
Other collar nuts on chassis
M6
15 Nm
M8
30 Nm
M10
50 Nm
10-72D
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
Connecting rod bearing
Cylinder 400
Cylinder 640
Cylinder 660
Piston forged
Piston cast
Piston rings end gap
Valves
Oil pumps
Bypaß valve
Clutch
Camshaft
Transmission shafts
Crankshaft webs – outer dimension
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm
run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm
radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 102.04 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm
oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm
seat sealing intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm
seat sealing exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm
run out of valve heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
valve guides diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm
clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm
Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm)
wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm
Length of the clutch spring 660 SMC . . . . . . . . . . min. 31.5 mm (new 33.5 mm)
diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 mm +/- 0.05 mm
11-1D
PERIODIC MAINTENANCE SCHEDULE
Art.-Nr. 321030-E
INDEX
MODEL 1998
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
SCHEDULE
SCHEDULE
SCHEDULE
SCHEDULE
SX, SXC, SC . . . . . . . . . .
LC4 COMPETITION, LC4
ADVENTURE-R . . . . . . .
DUKE . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.11-2
.11-3
.11-4
.11-5
MODEL1999
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
SCHEDULE
SCHEDULE
SCHEDULE
SCHEDULE
SX, SXC, SC . . . . . . . . . .
LC4 COMPETITION, LC4
ADVENTURE-R . . . . . . .
DUKE . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.11-6
.11-7
.11-8
.11-9
MODEL 2001
PERIODIC MAINTENANCE SCHEDULE 620 SC . . . . . . . . . . . . . . . . . .11-10
PERIODIC MAINTENANCE SCHEDULE LC4-E, ADVENTURE . . . . . . . .11-12
PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-14
Repair manual KTM LC4
MODEL 2002
PERIODIC MAINTENANCE SCHEDULE 625 SC . . . . . . . . . . . . . . . . . .11-16
PERIODIC MAINTENANCE SCHEDULE LC4, ADVENTURE . . . . . . . . . .11-18
PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-20
MODEL 2003
PERIODIC MAINTENANCE SCHEDULE 625 SXC, 660 SMC . . . . . . . . .11-22
PERIODIC MAINTENANCE SCHEDULE 640 LC4, 640 LC4 ADVENTURE . . .11-24
PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-26
11
11-2D
Art.-Nr. 3.206.006 -E
Check engine oil level
Change engine oil
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter unit
Change microfilter
Check oil lines for leakage and proper instalment
Check valve clearance
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Check valve clearance
Drain and clean carburator float bowl
Adjust idling
Check breather hoses of engine gase and gas tank for correct position without buckles
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Clean and lube chain
Check chain tension
Check cooling liquid level
Check quality of antifreeze
Check cooling system for leaks
Check exhaust system for leakage
Change exhaust muffler packing
Check exhaust brackets
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check brake discs
Check condition and correct instalment of brake hoses
Check freeplay and easy operation of hand brake lever and foot brake lever
Check adjustment and function of fork
Check fork for leaks
Perform a full maintenance job for the telescopic fork
Servicing the shock absorber
Grease lubricating nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system and perform a full maintenance job on it
Spray ignition lock, short circuit button, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding components
Check O-ring of the shock absorber for wear
Servicing swingarm pivots
Check tightness of spokes and rim join
Check wheel bearings for clearance
Check chock absorber rubbers on the rear wheel hub
Check tire condition and air pressure
Check cables for damage and easy working
Lube and adjust cables
Check the electrical system
Check adjustment of head light
Change fork oil
Clean dust scrabber on forks
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and funktion of shock absorber
Loosen breather screws at fork legs (overpressure)
Repair manual KTM LC4
at least once a year
after 5000 km
(3000 miles) or
once a year
1st service, after
1000 km (600 miles)
or 10 hours
after 2500 km
(1500 miles)
or 25 hours
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING
OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE
NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE
KTM
dealer
after washing
SX, SXC, SC
9.97
KTM
rider
before each start
PERIODIC MAINTENANCE SCHEDULE
11-3D
KTM
rider
PERIODIC MAINTENANCE SCHEDULE
after 5000 km
(3000 miles) or
once a year
at least once a year
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter insert
Change fine screen filter (screwed filter) at front pipe (of the frame)
Check oil lines for leakage and proper instalment without kinks
Check valve clearance
Check engine oil level
after washing
Change engine oil
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR
COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO
BE CARRIED OUT AFTER EACH RIDE OR RACE
before each start
1st service, after
500 km (300 miles)
400/640 LC4’98
620 LC4 Comp.’98
4. 98
KTM
dealer
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Drain and clean carburetor float chamber
Check all air supply and ventilation hoses of of the engine and of the carburetor for kinks
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Clean and lube chain
Check chain tension
Check cooling liquid level
Check exhaust system for leakage
Check exhaust brackets
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check brake discs
Check condition and correct instalment of brake hoses
Check free play and easy operation of foot brake pedal
Check adjustment and function of telescopic fork
Check telescopic fork for leaks
Loosen bleeder screws at fork legs (overpressure)
Change telescopic fork oil
Perform a full maintenance job for the telescopic fork
Clean dust scrabber of telescopic fork
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and funktion of shock absorber
Check quality of antifreezer
Check cooling system for leaks – visual check
Adjust idling
Check O-ring of the shock absorber for wear
Service the shock absorber
Grease nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it
Service swingarm pivot
Check spoke tension and join
Check wheel bearings for clearance
Check shock absorber rubbers on the rear hub
Check tire condition and air pressure
Check cables for damage and easy working
Lube and adjust cables
Check the electrical system
Check battery holder, battery and connections
Check adjustment of headlight
Spray ignition lock, emergency off switch, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding points
11-4D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check engine oil level
Change engine oil
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter insert
Change fine screen filter (screwed filter) at front pipe (of the frame)
Check oil lines for leakage and proper instalment without kinks
Check valve clearance
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Check ignition point
Drain and clean carburetor float chamber
Adjust idling
Check breather hoses of engine gase and gas tank for correct position without buckles
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Clean and lube chain
Check chain tension
Check cooling liquid level
Check quality of antifreezer
Check cooling system for leaks – visual check
Check exhaust system for leakage
Check exhaust brackets
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check brake discs
Check condition and correct instalment of brake hoses
Check free play and easy operation of foot brake pedal
Check adjustment and function of telescopic fork
Check telescopic fork for leaks
Loosen bleeder screws at fork legs (overpressure)
Change telescopic fork oil
Perform a full maintenance job for the telescopic fork
Clean dust scrabber of telescopic fork
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and funktion of shock absorber
Check O-ring of the shock absorber for wear
Service the shock absorber
Grease nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it
Service swingarm pivot
Check spoke tension and join
Check wheel bearings for clearance
Check shock absorber rubbers on the rear hub
Check tire condition and air pressure
Check cables for damage and easy working
Lube and adjust cables
Check the electrical system
Check battery holder, battery and connections
Check adjustment of headlight
Spray ignition lock, emergency off switch, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding points
at least once a year
after washing
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING
OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE
NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE
before each start
Adventure-R 3.98
after 5000 km
(3000 miles) or
once a year
KTM
dealer
after 2500 km
(1500 miles)
KTM
rider
1st service, after
500 km (300 miles)
PERIODIC MAINTENANCE SCHEDULE
11-5D
Check engine oil level
Change engine oil
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter insert
Change fine screen filter (screwed filter) at front pipe (of the frame)
Check oil lines for leakage and proper instalment without kinks
Check valve clearance
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Check ignition point
Drain and clean carburetor float chamber
Adjust idling
Check breather hoses of engine gase and gas tank for correct position without buckles
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Maintain chain tension eccentrics
Clean and lube chain
Check chain tension
Check cooling liquid level
Check quality of antifreezer
Check cooling system for leaks – visual check
Check exhaust system for leakage
Check exhaust brackets
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check brake discs
Check condition and correct instalment of brake hoses
Check free play and easy operation of foot brake pedal
Check adjustment and function of telescopic fork
Check telescopic fork for leaks
Change telescopic fork oil
Perform a full maintenance job for the telescopic fork
Clean dust scrabber of telescopic fork
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and funktion of shock absorber
Check O-ring of the shock absorber for wear
Service the shock absorber
Grease nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it
Service swingarm pivot
Check spoke tension and join
Check wheel bearings for clearance
Check shock absorber rubbers on the rear hub
Check tire condition and air pressure
Check cables for damage and easy working
Lube and adjust cables
Check the electrical system
Check battery holder, battery and connections
Check adjustment of headlight
Spray ignition lock, emergency off switch, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding points
at least once a year
after washing
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING
OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE
NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE
before each start
DUKE-E 2.98
after 5000 km
(3000 miles) or
once a year
KTM
dealer
after 2500 km
(1500 miles)
KTM
rider
1st service, after
500 km (300 miles)
PERIODIC MAINTENANCE SCHEDULE
11-6D
Change oil filter unit
at least once a year
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Check engine oil level
after washing
Change engine oil
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD
RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES)
SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE
before each start
after 2500 km
(1500 miles)
or 25 hours
KTM
dealer
1st service, after
1000 km (600 miles)
or 10 hours
2.99
620 SX
400/540 SXC
400/620 SC
KTM
rider
after 5000 km
(3000 miles) or
once a year
PERIODIC MAINTENANCE SCHEDULE
Change microfilter
Check oil lines for leakage and proper instalment
Check valve clearance
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Check valve clearance
Drain and clean carburetor float bowl
Check breather hoses of engine gase and gas tank for correct position without buckles
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Clean and lube chain
Check chain tension
Check cooling liquid level
Art.-Nr. 3.206.006 -E
Check exhaust system for leakage
Change exhaust muffler packing (aluminium-muffler)
Check exhaust brackets
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check brake discs
Check condition and correct instalment of brake hoses
Check freeplay and easy operation of hand brake lever and foot brake lever
Check adjustment and function of fork
Check fork for leaks
Loosen breather screws at fork legs (overpressure)
Change fork oil
Perform a full maintenance job for the telescopic fork
Clean dust scrabber on forks
Check steering head bearing clearance / adjust
Check adjustment and function of shock absorber
Check O-ring of the shock absorber for wear
Grease lubricating nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system and perform a full maintenance job on it
Servicing swingarm pivots
Check tightness of spokes and rim join
Check wheel bearings for clearance
Check tire condition and air pressure
Check cables for damage and easy working
Check adjustment of head light
Spray ignition lock, emergency OFF switch, short circuit button, and light switch with contact spray
Grease or lube all pivot points and sliding components
Lube and adjust cables
Check all bolts, nuts and hose clamps for proper tightness
Servicing the shock absorber
Check the electrical system
Clean and grease steering head bearings and its seals
Repair manual KTM LC4
Check quality of antifreeze
Check cooling system for leaks
Adjust idling
11-7D
Check engine oil level
at least once a year
after 5000 km
(3000 miles) or
once a year
1st service, after
500 km (300 miles)
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD
RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES)
SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE
before each start
400/640 LC4 ’99
400/640 LC4 R ’99
620 LC4 Comp.’99
620/640 Supermoto ‘99
10. 98
KTM
dealer
after washing
KTM
rider
PERIODIC MAINTENANCE SCHEDULE
Change engine oil
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter insert
Change fine screen filter (screwed filter) at front pipe (of the frame)
Check oil lines for leakage and proper instalment without kinks
Check valve clearance
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Drain and clean carburetor float chamber
Check all air supply and ventilation hoses of the engine and of the carburetor for kinks.
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Clean and lube chain
Check chain tension
Check cooling liquid level
Check quality of antifreezer
Check cooling system for leaks – visual check
Adjust idling
Check exhaust system for leakage
Check exhaust brackets
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check brake discs
Check condition and correct instalment of brake hoses
Check free play and easy operation of foot brake pedal
Check adjustment and function of telescopic fork
Check telescopic fork for leaks
Loosen bleeder screws at fork legs (overpressure)
Change telescopic fork oil
Perform a full maintenance job for the telescopic fork
Clean dust scrabber of telescopic fork
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and function of shock absorber
Check O-ring of the shock absorber for wear
Grease nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it
Service swingarm pivot
Check spoke tension and join
Check wheel bearings for clearance
Check shock absorber rubbers on the rear hub
Check tire condition and air pressure
Check cables for damage and easy working
Lube and adjust cables
Check battery holder, battery and connections
Check adjustment of headlight
Spray ignition lock, emergency off switch, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding points
Service the shock absorber
Check the electrical system
11-8D
KTM
rider
PERIODIC MAINTENANCE SCHEDULE
KTM
dealer
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
at least once a year
1st service, after
500 km (300 miles)
after 5000 km
(3000 miles) or
once a year
Check engine oil level
Change engine oil
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter insert
Change fine screen filter (screwed filter) at front pipe (of the frame)
Check oil lines for leakage and proper instalment without kinks
Check valve clearance
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Check ignition point
Drain and clean carburetor float chamber
Adjust idling
Check breather hoses of engine case and gas tank for correct position without buckles
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Clean and lube chain
Check chain tension
Check cooling liquid level
Check quality of antifreezer
Check cooling system for leaks – visual check
Check exhaust system for leakage
Check exhaust brackets
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check brake discs
Check condition and correct instalment of brake hoses
Check free play and easy operation of foot brake pedal
Check adjustment and function of telescopic fork
Check telescopic fork for leaks
Loosen bleeder screws at fork legs (overpressure)
Change telescopic fork oil
Perform a full maintenance job for the telescopic fork
Clean dust scrabber of telescopic fork
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and function of shock absorber
Check O-ring of the shock absorber for wear
Service the shock absorber
Grease nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it
Service swingarm pivot
Check spoke tension and join
Check wheel bearings for clearance
Check shock absorber rubbers on the rear hub
Check tire condition and air pressure
Check cables for damage and easy working
Lube and adjust cables
Check the electrical system
Check battery holder, battery and connections
Check adjustment of headlight
Spray ignition lock, emergency off switch, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding points
after washing
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD
RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES)
SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE
before each start
Adventure 09.98
11-9D
PERIODIC MAINTENANCE SCHEDULE
KTM
rider
KTM
dealer
after 5000 km
(3000 miles) or
once a year
at least once a year
Check oil lines for leakage and proper instalment without kinks
Check valve clearance
Check engine oil level
after washing
IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING, THE 5000 KM
(3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EVERY RACE
before each start
1st service, after
500 km (300 miles)
Duke 5.99
Change engine oil
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil
Change oil filter insert
Change fine screen filter (screwed filter) at front pipe (of the frame)
Clean spark plug and adjust electrode gap
Change spark plug after 10 000 kilometers (6 200 miles)
Drain and clean carburetor float chamber
Check breather hoses of engine gase and gas tank for correct position without buckles
Clean air filter and air filter box
Check sprockets, chain guides and chain for wear
Clean and lube chain
Check chain tension
Check cooling liquid level
Art.-Nr. 3.206.006 -E
Check quality of antifreezer
Check exhaust system for leakage
Check exhaust brackets
Clean spark arrestor discs (USA model)
Check brake fluid level front and rear
Change brake fluid
Check brake pad thickness
Check wear of brake discs
Check condition and correct instalment of brake hoses
Check free play and easy operation of foot brake pedal
Check adjustment and function of telescopic fork
Check telescopic fork for leaks
Loosen breather screws at fork legs (overpressure)
Change telescopic fork oil
Perform a full maintenance job for the telescopic fork
Check steering head bearing clearance / adjust
Clean and grease steering head bearings and its seals
Check adjustment and funktion of shock absorber
Repair manual KTM LC4
Check O-ring of the shock absorber for wear
Grease nipple of the Pro Lever suspension system
Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it
Service swingarm pivot
Check spoke tension and join
Check wheel bearings for clearance
Check tire condition and air pressure
Check cables for damage and easy working
Check shock absorber rubbers on the rear hub
Lube and adjust cables
Check battery holder, battery and connections
Check adjustment of headlight
Spray ignition lock, emergency off switch, and light switch with contact spray
Check all bolts, nuts and hose clamps for proper tightness
Grease or lube all pivot points and sliding points
Service the shock absorber
Check the electrical system
Maintain chain tension eccentrics
Check cooling system for leaks – visual check
Adjust idling
11-10D
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURATOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and micro-filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less
arrangement, adjust and lubricate
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function; (low/high beams, stop light, turn indicators,
tell-tale lamps, speedometer illumination, horn, emergency-off switch)
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join
Check tire condition and inflation pressure
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
Lubricate chain
Check wheel bearings and jerk damper for play
620 SC
1. Service after
1000 km
or
10 hours
after / every
2500 km
or
25 hours
after / every
5000 km
or
once a year
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IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
every 2500 km
or 25 hours
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Replace glass-fiber yarn packing of main silencer
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Change brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
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●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-11D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Verify smooth operation of all controls
Check brake performance
Btreat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit
before each
start
●
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after every
cleaning
for cross
country use
once a year
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11-12D
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and fine filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,
and adjust and lubricate them
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,
headlamp flasher, tell-tale lamps, speedometer illumination, horn,
side-stand switch, clutch switch, emergency-off switch)
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper operation
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join
Check tire condition and inflation pressure
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
Lubricate chain
Check wheel bearings and jerk damper for play
400/640 LC4-E
640 LC4 Adventure
2. Service after
5000 km, then
1. Service
every 5000 km or
after
once a year
1000 km
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●
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●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change the brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-13D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Verify smooth operation of all controls
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit
before each
start
●
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●
after every
cleaning
for cross
country use
once a year
●
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11-14D
PERIODIC MAINTENANCE SCHEDULE
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBUTATOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and fine filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper function
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,
adjust and lubricate
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,
headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand
switch, clutch switch, emergency-off switch)
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Service eccentric for chain tension
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check tire condition, inflation pressure, and rim condition
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
Lubricate chain
Check wheel bearings and jerk damper for play
640 Duke II
1. Service
after
1000 km
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2. Service after
5000 km, then
every 5000 km or
once a year
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●
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●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Replace glass-fiber yarn packing of the silencers
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change the brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-15D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper function
Check horn for proper function
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Verify smooth operation of all controls
Check braking performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit
before each
start
●
●
●
●
●
after every
cleaning
for competition use
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
11-16D
PERIODIC MAINTENANCE SCHEDULE 2002
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURATOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
1. Service after
1000 km
or
10 hours
Change engine oil, oil filter, and micro-filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
●
●
●
Check all engine bolts accessible from the outside for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less
arrangement, adjust and lubricate
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function; (low/high beams, stop light, turn indicators,
tell-tale lamps, horn)
●
Make sure all bolts and nuts are tight.
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join
Check tire condition and inflation pressure
●
●
●
●
●
●
Check chain and chain guides for wear, force fit and tension.
Check bolts on pinion and chain sprocket for locking devices and a tight fit.
Lubricate chain
Check wheel bearings and jerk damper for play
625 SC
625 SC SUPERMOTO
after / every
after / every
5000 km
2500 km
or
or
once a year
25 hours
●
●
●
●
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●
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●
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●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
every 2500 km
or 25 hours
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Replace glass-fiber yarn packing of main silencer
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Change brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-17D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Verify smooth operation of all controls
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for tight fit
before each
start
●
●
●
●
●
after every
cleaning
for cross
country use
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
11-18D
PERIODIC MAINTENANCE SCHEDULE 2002
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Change engine oil and oil filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check all engine bolts accessible from the outside for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight.
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper operation
Check O-ring of suspension strut for wear
Clean fork dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension.
Check bolts on pinion and chain sprocket for locking devices and a tight fit.
Lubricate chain
Check wheel bearings and jerk damper for play
640 LC4, LC4 SUPERMOTO
640 LC4 ADVENTURE
2. Service after
1. Service
5000 km, then
after
every 5000 km or
1000 km
once a year
●
●
●
●
●
●
●
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●
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●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change the brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-19D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean fork dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Check all control elements for smooth running
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit
before each
start
●
●
●
●
●
after every
cleaning
for cross
country use
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
11-20D
PERIODIC MAINTENANCE SCHEDULE 2002
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBUTATOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filter, and fine filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper function
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,
adjust and lubricate
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,
headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand
switch, clutch switch, emergency-off switch)
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Service eccentric for chain tension
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check tire condition, inflation pressure, and rim condition
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
Lubricate chain
Check wheel bearings and jerk damper for play
640 Duke II
1. Service
after
1000 km
●
●
●
2. Service after
5000 km, then
every 5000 km or
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Replace glass-fiber yarn packing of the silencers
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change the brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-21D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean fork dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Check all control elements for smooth running.
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit
before each
start
●
●
●
●
●
after every
cleaning
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
11-22D
PERIODIC MAINTENANCE SCHEDULE 2003
1. Service after
1000 km
or
10 hours
after / every
2500 km
or
25 hours
Change engine oil, oil filter, and micro-filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Make sure all engine bolts accessible from the outside are screwed tight
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less
arrangement, adjust and lubricate
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function; (low/high beams, stop light, turn indicators,
tell-tale lamps, horn, emergency-off switch)
●
●
●
●
●
Make sure all bolts and nuts are tight
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim join
Check tire condition and inflation pressure
●
●
●
●
●
●
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURATOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Check chain and chain guides for wear, force fit and tension
Check bolts on pinion and chain sprocket for locking devices and a tight fit
Lubricate chain
Check wheel bearings and jerk damper for play
625 SXC
660 SMC
after / every
5000 km
or
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
every 2500 km
or 25 hours
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Replace glass-fiber yarn packing of main silencer
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Change brake fluid
at least
once a year
every 2 years
or 20000 km
●
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-23D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box (depending on the dirt accumulation)
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Verify smooth operation of all controls
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for tight fit
before each
start
●
●
●
●
●
after every
cleaning
for cross
country use
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
11-24D
PERIODIC MAINTENANCE SCHEDULE 2003
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBURETOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
640 LC4, 640 LC4 SUPERMOTO
640 LC4 ADVENTURE
2. Service after
1. Service
5000 km, then
after
every 5000 km or
1000 km
once a year
Change engine oil, oil filter, and fine filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Make sure all engine bolts accessible from the outside are screwed tight
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper operation
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher,
tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight.
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/footbrake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper operation
Check O-ring of suspension strut for wear
Clean fork dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check spoke tension and rim joint
Check tire condition and inflation pressure
Check chain and chain guides for wear, force fit and tension.
Check bolts on pinion and chain sprocket for locking devices and a tight fit.
Lubricate chain
Check wheel bearings and jerk damper for play
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change the brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM.
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-25D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean fork dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box (depending on the dirt accumulation)
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Check all control elements for smooth running.
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit
before each
start
●
●
●
●
●
after every
cleaning
for cross
country use
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
11-26D
PERIODIC MAINTENANCE SCHEDULE 2003
WHEELS
CHASSIS
BRAKES
ADD-ON-PARTS
CARBUTATOR
ENGINE
A washed motorcycle can be checked more quickly which saves money!
Change engine oil, oil filters, and fine filter
Clean oil screens and magnet of drain plug
Check oil lines for damage and kink-less arrangement
Check and adjust spark plug, replace it every 10,000 km
Check and adjust valve clearance
Check engine fastening bolts for tight fit
Check carburetor connection boots for cracks and leaks
Check idle setting
Check bleeder hoses for damage and kink-free arrangement
Check cooling system for leaks, antifreeze protection
Check radiator fan for proper function
Check exhaust system for leaks and suspension
Check actuating cables for damage, smooth operation, and kink-less arrangement,
adjust and lubricate
Clean air filter and air filter box
Check cables for damage and kink-less arrangement
Check headlamp adjustment
Check electrical system for function (low/high beams, stop light, turn indicators,
headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand
switch, clutch switch, emergency-off switch)
Check brake fluid level, lining thickness, and brake discs
Check brake lines for damage and leaks
Check/adjust smooth operation, free travel of handbrake/foot brake levers
Check bolts of brake system for tight fit
Check suspension strut and fork for leaks and proper function
Check O-ring of suspension strut for wear
Clean dust sleeves
Bleed fork legs
Check swinging-fork pivot
Check/adjust steering-head bearing
Service eccentric for chain tension
Lubricate reversing lever
Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,
swinging-fork pivot, reversing lever, suspension strut)
Check tire condition, inflation pressure, and rim condition
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension
Lubricate chain
Check wheel bearings and jerk damper for play
640 Duke
1st Service
after
1000 km
●
●
●
2nd Service after
5000 km, then
every 5000 km or
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Perform complete fork maintenance
Perform complete suspension strut maintenance
Perform complete reversing lever maintenance
Replace glass-fiber yarn packing of the silencers
Clean and lubricate steering-head bearing and sealing elements
Clean and adjust the carburetor
Treat the electrical contacts and switches with contact spray
Treat battery connections with contact grease
Change the brake fluid
at least
once a year
●
every 2 years
or 20000 km
●
●
●
●
●
●
●
●
IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
11-27D
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
Check oil level
Check brake fluid level
Check brake pads for wear
Check lighting system for proper operation
Check horn for proper operation
Lubricate and adjust actuating cables and nipples
Bleed fork legs in regular intervals
Remove and clean fork dust sleeves in regular intervals
Clean and lubricate chain as necessary
Check chain tension
Clean air filter and filter box
Check tire pressure and wear
Check coolant level
Check fuel lines for leaks
Drain float chamber
Check all control elements for smooth running.
Check brake performance
Treat exposed metal components (except for the braking and exhaust
systems) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray
Check all bolts, nuts, and hose clamps for their tight fit
before each
start
●
●
●
●
●
after every
cleaning
once a year
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
12-1D
12
WIRING DIAGRAMS
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
INDEX
MODEL1998
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
400
400
400
400
640
640
640
620
400
640
/ 540 SXC . . . . . . . . . . . . . . . . . . . . . .12-3
/ 620 SC (For Competition) . . . . . . . . .12-5
/ 620 SC (For Australia) . . . . . . . . . . . .12-7
/ 620 SC (For Germany) . . . . . . . . . . . .12-9
LC4 (For USA) . . . . . . . . . . . . . . . . . . .1211
ADVENTURE-R (Dell Orto) . . . . . . . . .12-13
DUKE-E . . . . . . . . . . . . . . . . . . . . . . .12-15
LC4 COMPETITION . . . . . . . . . . . . . .12-17
LC4 . . . . . . . . . . . . . . . . . . . . . . . . .12-19
LC4 . . . . . . . . . . . . . . . . . . . . . . . . .12-21
MODEL 1999
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
400
400
400
400
640
640
640
620
400
640
640
/ 540 SXC . . . . . . . . . . . .
/ 540 SXC (Australia) . . . .
/ 620 SC . . . . . . . . . . . .
/ 620 SC (Australia) . . . . .
ADVENTURE-R (Dell Orto)
ADVENTURE-R (Mikuni) . .
DUKE . . . . . . . . . . . . . . .
LC4 COMPETITION . . . . .
LC4 . . . . . . . . . . . . . . . .
LC4, SUPERMOTO . . . . . .
LC4 (USA) . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
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.
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.
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.
.
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.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.12-23
.12-25
.12-27
.12-29
.12-13
.12-31
.12-33
.12-17
.12-19
.12-21
.12-11
MODEL 2000
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
400
640
640
400
640
400
/ 620 SC / 620 SC SUPERMOTO
ADVENTURE-R . . . . . . . . . . . .
DUKE . . . . . . . . . . . . . . . . . . .
LC4-E . . . . . . . . . . . . . . . . . . .
LC4-E, SUPERMOTO . . . . . . . .
/ 640 LC4-E (USA) . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.12-27
.12-31
.12-33
.12-19
.12-21
.12-35
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
12-2D
INDEX
MODEL 2001
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
620
640
640
400
640
SC / 620 SC SUPERMOTO . .
LC4 ADVENTURE . . . . . . . .
DUKE . . . . . . . . . . . . . . . . .
LC4-E, 400 / 640 LC4-E USA
LC4-E, SUPERMOTO . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.12-37
.12-39
.12-41
.12-43
.12-45
MODEL 2002
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
625
640
640
640
SC / 625 SC SUPERMOTO .
LC4 ADVENTURE . . . . . . .
DUKE . . . . . . . . . . . . . . . .
LC4, 640 LC4 SUPERMOTO
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.12-47
.12-49
.12-51
.12-53
.
.
.
.
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
WIRING DIAGRAM 640 LC4, 640 LC4 SUPERMOTO USA . . . .12-55
MODEL 2003
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
625
640
640
640
660
SXC . . . . . . . . . . . . . . . . .
LC4, 640 LC4 SUPERMOTO
LC4 ADVENTURE . . . . . . .
DUKE . . . . . . . . . . . . . . . .
SMC . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
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.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.12-57
.12-59
.12-61
.12-63
.12-64
12-3D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-4D
12-5D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-6D
12-7D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-8D
12-9D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-10D
KTM 400 / 640 SC 1998
12-11D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-12D
12-13D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-14D
12-15D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-16D
12-17D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-18D
12-19D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-20D
12-21D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-22D
12-23D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-24D
12-25D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-26D
12-27D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-28D
12-29D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-30D
12-31D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-32D
12-33D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-34D
12-35D
400/640 LC4
USA
Repair manual KTM LC4
400/640 LC4 USA 2000
Art.-Nr. 3.206.006 -E
12-36D
12-37D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-38D
KTM 620 SC 2001
12-39D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-40D
12-41D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-42D
12-43D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-44D
12-45D
Repair manual KTM LC4
KTM 640 LC4-E 2001
Art.-Nr. 3.206.006 -E
12-46D
12-47D
SERVICE
625 SuperComp. 2002
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-48D
KTM 625 SUPER COMPETITION 2002
12-49D
SERVICE
640 LC4 ADVENTURE
Repair manual KTM LC4
KTM 640 LC4 ADVENTURE 2002
Art.-Nr. 3.206.006 -E
12-50D
12-51D
SERVICE
DUKE 2002
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
KTM DUKE 2002
12-52D
12-53D
SERVICE
SERVICE
ax
MOTORCYCLE
Kabelstrangnummer:
Modell
640LC4-E
LC4 2002
2002
400/640
Datum, Name:
DIV. LÄNDER
Dateiname:
10.05.01 KE
LC42002
br
1
4
10
s
br
g
bl
br
br
2
v
br
ge-bl
ge-bl
br
w
v
3
Land:
vorne: 584.11.175.300
hinten: 584.11.176.200
7
33
w
9
s
8
bl
6
g-s
5
ge-s
11
START
NOT-
g-s
ge
g
o
bl
r-w
ge
w
g-r
g-s
g-br
bl-r
bl-s
g
r-br
40
br
ge
g
bl
w
ge-bl
o
v
s
gr
br
v
ge-bl
ge-s
g-s
bl
s
w
br
47
11
11
ge-bl
g-r
o
r
o
r-w
ge
42
44
g-r
r-s
s-o
bl-s
ge-bl
br
bl-w
31
ge-bl
14
29
30
r
o
o
ge-bl
31
s
ge-r
ge-r
ge-bl
br
v
ge-bl
ge-s
g-s
bl
s
w
br
12
s-w
o
bl
s
s-ge
AUS
35
ELECTRONIC
POWERCONTROL
28
ge-bl
r-s
br
43
49
s-o
50
bl-s
ge-bl
gr
g-s
ge
48
16
g-w
15
g-s
17
ge-s
18
28
ge-bl
o
o
53
br
20
29
ge-s
g-s
s-o
bl-s
23
ge-bl
21
bl-w
13
36
br
KOKUSAN
r
s-w
ge
ge
ge
s
g-s
48
19
g-w
ge-s
g-s
s-o
bl-s
52
KOKUSAN
br
41
ge-r
br
28
r-w
br
13
br
37
g-w
br
w
v
s
s
r
g
w
ge-r
br
38
ge
r-s
s-r
M
bl-w
s-r
r-s
s-w
o
g
w
s
32
34
45
22
G
13
46
KOKUSAN 12V 200W
s
v
13
25
39
26
br
51
br
24
g-w
br
w
v
s
30
27
KOKUSAN
12-54D
Repair manual KTM LC4
Spanisch
KTM 640
LC4 2002
2002
KTM 400/640
LC4-E
Art.-Nr. 3.206.006 -E
Deutsch
Englisch
1 Scheinwerfer
2 Standlicht
3 Blinker li vo
4 Blinker re vo
5 Temperaturkontrolle
6 Leerlaufanzeige
7 Tachobeleuchtung
8 Fernlichtkontrolle
9 Blinkerkontrolle
10 Z ndschlo§
11 Sicherung 10A
12 zum Kombischalter
13 Masseanschlu§
14 Blinkgeber
15 Horn
16 Bremslichtsch. vo
17 Leerlaufschalter (N)
18 Thermoschalter
19 Bremslichtsch. hi
20 Z ndkerze
21 Z ndspule
22 Generator
23 Regelgleichrichter
24 Blinker li hi
25 Blinker re hi
26 Brems-Schlu§licht
27 CDI-Einheit
28 2-pol.Stecker
29 4-pol.Stecker
30 6-pol.Stecker
31 9-pol.Stecker
32 Hauptsicherung 20A
33 Starttast.Notaussch.
34 Batterie 12V 8Ah
35 EPC
36 L ftermotor
37 Startrelaise
38 Startermotor
39 Kennzeichenbeleuchtung
40 Kupplungsschalter
41 Thermoschalter
42 Starterhilfsrelais
43 Vergaserschalter
44 Magnetventil
45 Kondensator
46 Impulsgeber
47 12-pol.Stecker
48 Diode
49 Kontaktstift 3.Gang
50 Kontaktstift 2.Gang
51 3-pol.Stecker
52 Seitenst nderrelais
53 Seitenst nderschalter
Italienisch
1 headlight
2 parking light
3 blinker left front
4 blinker right front
5 temperature control
6 neutral
7 tachometer light
8 high beam control
9 blink control
10 ignition switch
11 fuse 10A
12 to combinat. switch
13 ground connection
14 blink signal system
15 horn
16 stoplight switch f.
17 idle switch (N)
18 temperature switch
19 stoplight switch r.
20 spark plug
21 ignition coil
22 generator
23 regulator-rectifier
24 blinker left rear
25 blinker right rear
26 rear-stoplight
27 CDI-unit
28 multip.cont.plug (2)
29 multip.cont.plug (4)
30 multip.cont.plug (6)
31 multip.cont.plug (9)
32 mainfuse 20A
33 run-off/start switch
34 battery 12V 8Ah
35 EPC
36 fan motor
37 starter relay
38 starter engine
39 licence plate lighting
40 clutch switch
41 temperature switch
42 startar auxil. relay
43 carburetor switch
44 magnetic valve
45 capacitor
46 pulser coil
47 multip.cont.plug (12)
48 diode
49 gear switch 3rd gear
50 gear switch 2th gear
51 multip.cont.plug (3)
52 sidestand relay
53 side stand switch
1 faro
2 luz de posicion
3 interm. izquierdo delantero
4 intermitente derecho delantero
5 control temperatura
6 indicador punto muerto
7 luz tacometro
8 lampara aviso luces largas
9 lampara aviso intermitentes
10 llave de contacto
11 fusible 10A
12 interruptor combinado
13 conector a masa
14 conjunto del intermitente
15 claxon
16 interruptor
17 interruptor punto muerto
18 interruptor temperatura
Franz sisch
1 faro
2 luce di posizione
3 lampegg. ant. sn.
4 lampegg. ant. dx.
5 controllo temperatura
6 indicat.marcia folle
7 luce di tachimetro
8 spia abbagliante
9 spia lampeggiatori
10 int. accensione
11 fusibile 10A
12 multicomando
13 collegam. a massa
14 trasmett. di lampeg.
15 clacson
16 int.luce arresto ant.
17 interr.luce folle (N)
18 int. temperatura
19 int.luce arresto post
20 candela
21 bobina d’accens.
22 dinamo
23 regolatore di tens
24 lampegg. post. sn.
25 lampegg. post. dx.
26 fanal.post.di freno
27 CDI-seatola
28 connettore a 2 poli
29 connettore a 4 poli
30 connettore a 6 poli
31 connettore a 9 poli
32 fusibile principale 20A
33 disinseritor/partire
34 batteria 12V 8Ah
35 EPC
36 ventilatore
37 rele d’avviamento
38 mot.d’avviamento elettr.
39 illuminat.de.targa
40 interrutore frizione
41 int. temperatura
42 rele avviam. ausiliario
43 interrutore carburatore
44 valvola elettromagnetica
45 condensatore
46 trasmettitore d’impulsi
47 connettore a 12 poli
48 diodo
49 3.secondo marcia
50 2.secondo marcia
51 connettore a 3 poli
52 rele del cavalleto later
53 int del cavalleto later
1 phare
2 feu de position
3 clignoteur av. gauche
4 clignoteur av. droit
5 temoin de temperature
6 ind.de point mort
7 eclair.comp.vitesse
8 temoin de feu route
9 temoin de clignoteur
10 contact.d’allum.
11 fusible 10A
12 vers commutateur
13 masse
14 centrale clignot.
15 klaxon
16 cont.av de stop
17 contact.pt.mort (N)
18 contact. de temperature
19 contact.arr.de stop
20 bougie
21 bobine d’allumage
22 generateur
23 regulat.redresseur
24 clign.arr.gauche
25 clign.arr.droit
26 feu arr.et de stop
27 boitier CDI
28 connect.multiple (2)
29 connect.multiple (4)
30 connect.multiple (6)
31 connect.multiple (9)
32 fusible principal 20A
33 bout.de demar/arr.d’urg
34 batterie 12V 8Ah
35 EPC
36 ventilateur
37 relaise de demarreur
38 demarreur electrique
39 ecl.plaque d.immat.
40 contact.de embrayage
41 contact.de temperature
42 relaise auxi demarrage
43 contact.de carburateur
44 electrovanne
45 condensateur
46 capteur
47 connect.multiple (12)
48 diode
49 cont.d.boite d.vites.(3)
50 cont.d.bolte.d.vites.(2)
51 connect.multiple (3)
52 relaise com de bequ lat
53 commut de bequille later
37 rele de arranque
38 motor de arranque
39 luz plaza de matricula
40 interruptor de embraque
41 interruptor temperatura
42 rele del arranque
43 interruptor de carburador
44 valvola magnetica
45 condensador
46 generado de impulsos
47 conector multiple (12)
48 diodo
49 interruptor de cambio (3)
50 interruptor de cambio (2)
51 conector multiple (3)
52 rele del caballete lateral
53 int.del caballete lateral
19 interruptor luz de frendo tras
20 bujia
21 bobina de encendido
22 generador
23 regulador de tension
24 intermitente izquierdo trasero
25 intermitente derecho trasero
26 luz de freno trasero
27 unidad cdi
28 conecdor multiple (2)
29 conector multiple (4)
30 conector multiple (6)
31 conector multiple (9)
32 fusible principal 20A
33 boton de arranque par.de urg.
34 bateria 12V 8 Ah
35 EPC
36 ventilador electrica
Start- Notaus- Schalter
Deutsch
bl blau
br braun
ge gelb
gr grau
g gr n
o orange
r rot
ra rosa
s schwarz
v violett
w wei§
Englisch
bl blue
br brown
ge yellow
gr grey
g green
o orange
r red
ra pink
s black
v violet
w white
Italienisch
bl blu
br marrone
ge giallo
gr grigio
g verde
o arancione
r rosso
ra rosa
s nero
v violetto
w bianco
Franz sisch
bl bleu
br brun
ge jaune
gr gris
g vert
o orange
r rouge
ra rose
s noir
v violet
w blanc
Kombischalter
Spanisch
bl azul
br marron
ge amarillo
gr gris
g verde
o naranja
r rojo
ra rosado
s negro
v violeta
w blanco
br
ge
w
bl- blr s
gbr
g
gs
o
Domino
sge bl
s
sw
rw
bl
TURN L
TURN R
Z ndschlo§ (Typ Zadi)
LIGHTS
o
H LO
H HI
HORN
PASSING
g
ge
gs
12-55D
SERVICE
SERVICE
ax
MOTORCYCLE
Kabelstrangnummer:
Modell
Datum, Name:
USA
Dateiname:
10.05.01 KE
LC42002
br
1
4
10
s
br
g
bl
br
br
2
v
br
ge-bl
ge-bl
br
w
v
3
Land:
vorne: 584.11.175.300
hinten: 584.11.176.200
640
LC4USA
USA
2002
640
LC4-E
2002
7
33
w
9
s
8
bl
6
g-s
5
ge-s
11
START
NOT-
g-s
ge
g
o
bl
r-w
ge
w
g-r
g-s
g-br
bl-r
bl-s
g
r-br
40
br
ge
g
bl
w
ge-bl
o
v
s
gr
br
v
ge-bl
ge-s
g-s
bl
s
w
br
47
11
11
ge-bl
g-r
31
ge-bl
14
29
30
r
o
o
ge-bl
31
s
ge-r
ge-r
ge-bl
br
v
ge-bl
ge-s
g-s
bl
s
w
br
12
s-w
o
bl
s
s-ge
AUS
o
r
o
r-w
ge
42
28
ge-bl
r-s
br
ge-bl
gr
s-o
bl-s
g-s
ge
48
16
g-w
15
g-s
17
ge-s
18
28
ge-bl
o
o
53
br
20
29
ge-s
g-s
s-o
bl-s
23
ge-bl
21
bl-w
13
36
br
KOKUSAN
r
s-w
ge
ge
ge
s
g-s
48
19
g-w
ge-s
g-s
s-o
bl-s
52
KOKUSAN
br
41
ge-r
br
28
r-w
br
13
br
37
g-w
br
w
v
s
s
r
g
w
ge-r
br
38
ge
r-s
s-r
M
bl-w
s-r
r-s
s-w
o
g
w
s
32
34
45
22
G
13
46
KOKUSAN 12V 200W
s
v
13
25
39
26
br
51
br
24
g-w
br
w
v
s
30
27
KOKUSAN
12-56D
Repair manual KTM LC4
Spanisch
LC4USA
USA2002
2002
KTMKTM
640 640
LC4-E
Art.-Nr. 3.206.006 -E
Deutsch
Englisch
Italienisch
Franz sisch
1 Scheinwerfer
2 Standlicht
3 Blinker li vo
4 Blinker re vo
5 Temperaturkontrolle
6 Leerlaufanzeige
7 Tachobeleuchtung
8 Fernlichtkontrolle
9 Blinkerkontrolle
10 Z ndschlo§
11 Sicherung 10A
12 zum Kombischalter
13 Masseanschlu§
14 Blinkgeber
15 Horn
16 Bremslichtsch. vo
17 Leerlaufschalter (N)
18 Thermoschalter
19 Bremslichtsch. hi
20 Z ndkerze
21 Z ndspule
22 Generator
23 Regelgleichrichter
24 Blinker li hi
25 Blinker re hi
26 Brems-Schlu§licht
27 CDI-Einheit
28 2-pol.Stecker
29 4-pol.Stecker
30 6-pol.Stecker
31 9-pol.Stecker
32 Hauptsicherung 20A
33 Starttast.Notaussch.
34 Batterie 12V 8Ah
1 headlight
2 parking light
3 blinker left front
4 blinker right front
5 temperature control
6 neutral
7 tachometer light
8 high beam control
9 blink control
10 ignition switch
11 fuse 10A
12 to combinat. switch
13 ground connection
14 blink signal system
15 horn
16 stoplight switch f.
17 idle switch (N)
18 temperature switch
19 stoplight switch r.
20 spark plug
21 ignition coil
22 generator
23 regulator-rectifier
24 blinker left rear
25 blinker right rear
26 rear-stoplight
27 CDI-unit
28 multip.cont.plug (2)
29 multip.cont.plug (4)
30 multip.cont.plug (6)
31 multip.cont.plug (9)
32 mainfuse 20A
33 run-off/start switch
34 battery 12V 8Ah
1 faro
2 luce di posizione
3 lampegg. ant. sn.
4 lampegg. ant. dx.
5 controllo temperatura
6 indicat.marcia folle
7 luce di tachimetro
8 spia abbagliante
9 spia lampeggiatori
10 int. accensione
11 fusibile 10A
12 multicomando
13 collegam. a massa
14 trasmett. di lampeg.
15 clacson
16 int.luce arresto ant.
17 interr.luce folle (N)
18 int. temperatura
19 int.luce arresto post
20 candela
21 bobina d’accens.
22 dinamo
23 regolatore di tens
24 lampegg. post. sn.
25 lampegg. post. dx.
26 fanal.post.di freno
27 CDI-seatola
28 connettore a 2 poli
29 connettore a 4 poli
30 connettore a 6 poli
31 connettore a 9 poli
32 fusibile principale 20A
33 disinseritor/partire
34 batteria 12V 8Ah
1 phare
2 feu de position
3 clignoteur av. gauche
4 clignoteur av. droit
5 temoin de temperature
6 ind.de point mort
7 eclair.comp.vitesse
8 temoin de feu route
9 temoin de clignoteur
10 contact.d’allum.
11 fusible 10A
12 vers commutateur
13 masse
14 centrale clignot.
15 klaxon
16 cont.av de stop
17 contact.pt.mort (N)
18 contact. de temperature
19 contact.arr.de stop
20 bougie
21 bobine d’allumage
22 generateur
23 regulat.redresseur
24 clign.arr.gauche
25 clign.arr.droit
26 feu arr.et de stop
27 boitier CDI
28 connect.multiple (2)
29 connect.multiple (4)
30 connect.multiple (6)
31 connect.multiple (9)
32 fusible principal 20A
33 bout.de demar/arr.d’urg
34 batterie 12V 8Ah
36 L ftermotor
37 Startrelaise
38 Startermotor
39 Kennzeichenbeleuchtung
40 Kupplungsschalter
41 Thermoschalter
42 Starterhilfsrelais
36 fan motor
37 starter relay
38 starter engine
39 licence plate lighting
40 clutch switch
41 temperature switch
42 startar auxil. relay
36 ventilatore
37 rele d’avviamento
38 mot.d’avviamento elettr.
39 illuminat.de.targa
40 interrutore frizione
41 int. temperatura
42 rele avviam. ausiliario
36 ventilateur
37 relaise de demarreur
38 demarreur electrique
39 ecl.plaque d.immat.
40 contact.de embrayage
41 contact.de temperature
42 relaise auxi demarrage
45 Kondensator
46 Impulsgeber
47 12-pol.Stecker
48 Diode
45 capacitor
46 pulser coil
47 multip.cont.plug (12)
48 diode
45 condensatore
46 trasmettitore d’impulsi
47 connettore a 12 poli
48 diodo
45 condensateur
46 capteur
47 connect.multiple (12)
48 diode
51 3-pol.Stecker
52 Seitenst nderrelais
53 Seitenst nderschalter
51 multip.cont.plug (3)
52 sidestand relay
53 side stand switch
51 connettore a 3 poli
52 rele del cavalleto later
53 int del cavalleto later
51 connect.multiple (3)
52 relaise com de bequ lat
53 commut de bequille later
1 faro
2 luz de posicion
3 interm. izquierdo delantero
4 intermitente derecho delantero
5 control temperatura
6 indicador punto muerto
7 luz tacometro
8 lampara aviso luces largas
9 lampara aviso intermitentes
10 llave de contacto
11 fusible 10A
12 interruptor combinado
13 conector a masa
14 conjunto del intermitente
15 claxon
16 interruptor
17 interruptor punto muerto
18 interruptor temperatura
37 rele de arranque
38 motor de arranque
39 luz plaza de matricula
40 interruptor de embraque
41 interruptor temperatura
42 rele del arranque
19 interruptor luz de frendo tras
20 bujia
21 bobina de encendido
22 generador
23 regulador de tension
24 intermitente izquierdo trasero
25 intermitente derecho trasero
26 luz de freno trasero
27 unidad cdi
28 conecdor multiple (2)
29 conector multiple (4)
30 conector multiple (6)
31 conector multiple (9)
32 fusible principal 20A
33 boton de arranque par.de urg.
34 bateria 12V 8 Ah
45 condensador
46 generado de impulsos
47 conector multiple (12)
48 diodo
51 conector multiple (3)
52 rele del caballete lateral
53 int.del caballete lateral
36 ventilador electrica
Start- Notaus- Schalter
Deutsch
bl blau
br braun
ge gelb
gr grau
g gr n
o orange
r rot
ra rosa
s schwarz
v violett
w wei§
Englisch
bl blue
br brown
ge yellow
gr grey
g green
o orange
r red
ra pink
s black
v violet
w white
Italienisch
bl blu
br marrone
ge giallo
gr grigio
g verde
o arancione
r rosso
ra rosa
s nero
v violetto
w bianco
Franz sisch
bl bleu
br brun
ge jaune
gr gris
g vert
o orange
r rouge
ra rose
s noir
v violet
w blanc
Kombischalter
Spanisch
bl azul
br marron
ge amarillo
gr gris
g verde
o naranja
r rojo
ra rosado
s negro
v violeta
w blanco
br
ge
bl- blw
r s
gbr
g
gs
o
Domino
sge bl
s
sw
rw
bl
TURN L
TURN R
Z ndschlo§Æ (Typ Zadi)
LIGHTS
o
H LO
H HI
HORN
PASSING
g
ge
gs
12-57D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-58D
12-59D
640 LC4 2003
Repair manual KTM LC4
KTM 640 LC4 2003
Art.-Nr. 3.206.006 -E
12-60D
12-61D
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-62D
flasher control lamp
temperature control lamp
ye-bl
ye-bu
left front flasher
right front flasher
bl
pu
v
speedometer
n
idle control lamp
tachometer
headlight
bu
br
gn-bl
ye-bu
br
bl
pu
br
br
wh
ye-bu
bu-wh
wh
br
wh
br
or
br
gn
wh
ye-bl
gn-bl
br
bu-wh
wh
bu
gn-bl
ye
2nd
pi
3th
br-pi
br
neutral switch
2nd gear
3th gear
temperature sensor
t∞
bu-re
pu
front
brake switch
640-Duke 03
sidestand switch
br
ye
N
ye-wh
ye-br
bl-wh
or
or
ye-bu
M
cooling fan
A
10
A
10
A
10
fuse box
ye-bu
re-wh
br
bl-or
or
br
wiring diagram
EPC
wh
wh
or
G
bu
ye-bu
ye-bu
bl
pu
or
gn
bu
gr
ye-bl
gn-wh
pi
clutch switch
horn
ye
br
driving light lamp
gn-bl
gn
re-ye
ye
re-gn
0
ye-bu
head light flascher
ye
gn
ye-bl
gn-re
gn-br
ye-br
or
bu-bl
bu-bl
bl
or-bl
gr
gn-bl
bl-bu
or
re
ignition coil
bl
bl-or
bu-wh
br
1
starter motor
ye-re
M
octane selector
ignition switch
br-bl
br
C_AF1/4
+
gn
battery
ye
TPS
bl
or
ye
re
re-wh
main harness - 587.11.075.100
cockpit - 587.11.082.000
rear - 587.11.076.200
fuse box - 587.11.087.000
Pick up
capacitor
_
20
A
start relay
br
light switch
br-bl
re-gn
diode
2
bu-wh
temperature switch
br-bl
or-bl
diode
pi
re
start/stop switch
ye
re-wh
bl
re-wh
bu
ye
bl
re
wh
re-wh
flasher relay
bu-bl
C
re-ye
ye
D
re
gn
I
re
Art.-Nr. 3.206.006 -E
br-bl
br
re
wh
high/low beam switch horn switch
flasher switch
bu
Repair manual KTM LC4
gn-wh
wh
br
wh
bl
br
pu
gn-wh
ye-bu
rear
brake switch
start auxillary relay
br
re
3
left raer flasher
licence plate lamp
right rear flasher
generator
G
U
regulator-rectifier
12-63D
rear light/brakelight
12-64D
660 SMC 2003
Repair manual KTM LC4
Art.-Nr. 3.206.006 -E
12-65D
KTM 660 SMC 2003